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

19A-42
COOLING
Water chamber: Removal - Refitting
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 engine cover. Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Tightening torquesm
water chamber bolts10 N.m
intercooler air outlet
pipe clip at the damper
valve end5.5 N.m
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 does not operate using pure water.
WARNING
Take care not to damage the bearing faces to pre-
vent any risk of coolant leaks.

19A-44
COOLING
Water chamber: Removal - Refitting
K9K
19A
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aUnclip the cooling hose of the coolant-oil heat ex-
changer at (11) .
aMove aside the cooling hose of the coolant-oil heat
exchanger.
aSeparate the clips of the water chamber cooling hos-
es (12) using the (Mot. 1448).
aDisconnect:
-the water chamber cooling hoses (12) ,
-the coolant temperature sensor connector.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the water chamber bolts (13) ,
-the water chamber,
-the water chamber seal.
aTurn the thermostat one quarter of a turn.
aRemove the thermostat from the water chamber.
REFITTING
I - REFITTING PREPARATION OPERATION
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) to clean and degrease.
aparts always to be replaced: Cylinder head cool-
ant outlet unit seal
141218
121416121416
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 mar ks).

19A-46
COOLING
Water chamber: Removal - Refitting
D4F, and 780 or 782
19A
REMOVAL - REFITTING
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDetach the turbocharger cooling pipe from the cylin-
der head.
aRemove the water chamber hose clips using the
(Mot. 1448).
aDisconnect the water chamber hoses.
aRemove the pipe from the heater matrix under the
water chamber.aRemove:
-the water chamber bolts (1) ,
-the water chamber (2) ,
-the water chamber seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the water chamber seal.
II - REFITTING OPERATION FOR PART
CONCERNED
aPosition the water chamber with a new seal.
aScrew on the water chamber bolts without tightening
them.
aTorque tighten the water chamber bolts (10 N.m).
aConnect the water chamber hoses.
aFit the heater matrix pipe under the water chamber.
aRefit the water chamber hose clips using the (Mot.
1448).
aClip the turbocharger cooling pipe onto the cylinder
head. Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Tightening torquesm
water chamber bolts10 N.m
Note:
Use a cloth to protect the TDC sensor to prevent
any coolant entering the opening on the gearbox.
113372
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).

19A-48
COOLING
Water chamber: 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).
aRemove:
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the engine undertray.
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) . Special tooling required
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)
Tightening torquesm
water chamber bolts
(initial torque)4 N.m
water chamber bolts12 N.m
heater matrix hose
bracket bolt10 N.m
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
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
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.

19A-49
COOLING
Water chamber: Removal - Refitting
K4M
19A
aUsing the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) remove:
-the cooling radiator top hose clip on the water
chamber,
-the heater matrix hose clip (1) on the water cham-
ber.
aDisconnect from the water chamber:
-the cooling radiator top hose,
-the heater matrix hose.
aRemove:
-the bolt (2) from the heater matrix hose bracket,
-the heater matrix hose bracket,
-the bolts (3) of the engine wiring channel,
-the coolant temperature sensor (see 19A, Cool-
ing, Coolant temperature sensor: Removal - Re-
fitting, page 19A-66) .
aMove aside the engine wiring channel.
aUnclip the wiring at (4) .II - REMOVAL OPERATION
aRemove:
-the coolant outlet unit bolts,
-the water chamber,
-the water chamber seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Cylinder head cool-
ant outlet unit seal.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the cylinder head joint face,
-the coolant outlet unit housing if it is being reused.
132444
128456
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).

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-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-71
COOLING
Coolant temperature sensor: Removal - Refitting
K4M
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .II - REMOVAL OPERATION
aDisconnect the coolant temperature sensor connec-
tor (1) .
aRemove:
-the coolant temperature sensor clip (2) ,
-the coolant temperature sensor,
-the coolant temperature sensor seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: coolant tempera-
ture sensor seal.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the seal housing in the water chamber,
-the seal mating face of the coolant temperature
sensor if reused.
II - REFITTING OPERATION
aRefit:
-the coolant temperature sensor fitted with a new
seal,
-the coolant temperature sensor clip.
aConnect the coolant temperature sensor connector. IMPORTANT
The circuits are designed to be pressurised, so be
careful at high temperatures (risk of serious burns).
Do not remove the cap from the expansion bottle
while the engine is hot.
Take care when carrying out a repair under the bon-
net, as the radiator fan(s) may start to operate with-
out warning.
Do not open the bleed screw(s) with the engine run-
ning.
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.
131762

19B-9
EXHAUST
Exhaust: Precautions for the repair
19B
Before cutting the exhaust system, draw a line (D) be-
tween the two marks (P1) and (P2) .
The distance between the two marks on the exhaust
pipe is (X1) : 90 mm (all types except RENAULT
SPORT).
The distance between the two marks on the exhaust
pipe is (X1) : 80 mm (RENAULT SPORT).
3 - Operate tool Mot. 1199-01Fit the (Mot. 1199-01) (1) on the exhaust pipe.
Tighten the two bolts on the tool until they touch the
pipe in order to clamp the tool onto the pipe.
Turn the cutting tool using the handle and pressing it
against the pipe (as indicated in the diagram above).
Tighten the two bolts on the tool whilst cutting, until the
pipe is completely cut.
Once the pipe is cut, file and deburr the end of the pipe
to be used on the vehicle again.
4 - Positioning the exhaust trunking
100649
Note:
For CLIO II RENAULT SPORT with F4R*730,
F4R*732 and F4R*736 engines, the cutting area is
shown by a single mark on the exhaust pipe.
Cut the exhaust pipe by placing the (Mot. 1199-01)
on the mark.
14747
102118
Note:
Do not over-tighten the tool onto the pipe to avoid
deforming it.
WARNING
Do not reuse an old exhaust trunking.

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.