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

11A-125
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
11A
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 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).
aRemove:
-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 accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-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) .
aRemove:
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the intake distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) .
aRemove:
-the inlet manifold (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-the air filter box retaining belts,
-the air filter unit.
aRemove:
-the ignition coil (see 17A, Ignition, Coils: Remov-
al - Refitting, page 17A-1) ,
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) .
aPerform the following operations:
-drain the engine oil (see 10A, Engine and cylin-
der block assembly, Engine oil: Draining - Re-
filling, page 10A-22) ,
-drain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aRemove the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29) . 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
cylinder head bolts (ini-
tial torque)20 N.m
cylinder head bolts230˚ ±± ± ±
6
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
D4F
D4F
D7F

11A-127
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
11A
1 - Cleaning the cylinder head
aApply SUPER CLEANER FOR JOINT FACES (see
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products) to the areas to be
cleaned.
aWait for approximately ten minutes.
aRemove the residue using a wooden spatula.
aComplete the cleaning operation using a grey abra-
sive pad.
2 - Checking the gasket face
aCheck the flatness of the cylinder head gasket face
(see Cylinder head: Check) .3 - Optional additional operations
aWhen replacing the cylinder head, strip the cylinder
head (see Cylinder head: Stripping - Rebuilding) .
aIf necessary, carry out a complete check of the cylin-
der head (see Cylinder head: Check) .
II - REFITTING OPERATION FOR PART
CONCERNED
aBring the pistons to mid-stroke position to prevent
them from coming into contact with the valves during
the tightening of the cylinder head.
aCheck for the cylinder head centring dowels on the
cylinder block.
aRefit:
-a new cylinder head gasket,
-the cylinder head.
Cylinder head tightening procedure
aRefit the new cylinder head bolts.
aFit the cylinder head bolts, without tightening them. 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
Do not allow this product to drip onto the paint-
work.
Clean the cylinder head carefully to avoid any
foreign bodies entering the oil return and supply
pipes.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.
WARNING
Protect the oilway so that foreign bodies do not
enter the oil pipes in the cylinder head.
Failure to follow this instruction could lead to the
blocking of the oilways, resulting in a rapid deteri-
oration of the camshaft.
Note:
The cylinder head bolts must not be lubricated
before being fitted.
WARNING
No regrinding of the cylinder head is permitted.
WARNING
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.

11A-128
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
11A
aTighten to torque and in order the cylinder head
bolts (initial torque) (20 N.m).
aCheck that all the cylinder head bolts are pretight-
ened to 20 Nm.
aAngle tighten in order the cylinder head bolts (230˚
±± ± ±
6).
III - FINAL OPERATION
aRefit the exhaust bracket bolts.
aTighten the exhaust bracket bolts.
aConnect the water chamber hoses.
aFit the water chamber hose clips using the tool (Mot.
1448) or (Mot. 1202-01) or (Mot. 1202-02).
aConnect the coolant temperature sensor connector.
aRefit:
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) ,
-the ignition coil.
aRefit:
-the inlet manifold (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
aRefit:
-the air filter unit,
-the air filter box retaining belts,
-the intake distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) .
aRefit:
-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 accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) .
aRefit:
-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).
aRefit:
-a new oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29) ,
-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).
aPerform the following operations:
-top up the engine oil (see 10A, Engine and cylin-
der block assembly, Engine oil: Draining - Re-
filling, page 10A-22) ,
18641
D4F
D7F
D4F

11A-132
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
aMove aside the clips (7) from the cooling hoses us-
ing the (Mot. 1448).
aDisconnect the cooling hoses.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the cylinder head bolts,
-the cylinder head,
-the cylinder head gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Cylinder head gas-
ket.
aparts always to be replaced: cylinder head bolts.
1 - Cleaning the cylinder head
aApply SUPER CLEANER FOR JOINT FACES (see
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products) to the areas to be
cleaned.
aWait for approximately ten minutes.
aRemove the residue using a wooden spatula.
aFinish cleaning with a grey abrasive pad.
121723
18641
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
Do not allow this product to dr ip onto the paint-
work.
Clean the cylinder head carefully to prevent for-
eign bodies from entering the oil supply and
return galleries.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.
WARNING
Protect the oilway so that foreign bodies do not
enter the oil pipes in the cylinder head.
Failure to follow this instruction could lead to the
blocking of the oilways, resulting in a rapid deteri-
oration of the camshaft.
Note:
The cylinder head bolts must not be lubricated
before being fitted.

11A-133
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
2 - Checking the gasket face
aCheck the flatness of the cylinder head gasket face
(see Cylinder head: Check) .
3 - Optional additional operations
aWhen replacing the cylinder head, strip the cylinder
head (see Cylinder head: Stripping - Rebuilding) .
aIf necessary, carry out a complete check of the cylin-
der head (see Cylinder head: Check) .
II - REFITTING OPERATION FOR PART
CONCERNED
aBring the pistons to mid-stroke position to prevent
them from coming into contact with the valves during
the tightening of the cylinder head.
aCheck for the cylinder head centring dowels on the
cylinder block.
aFit a new cylinder head gasket onto the cylinder
block, positioning the marking (8) on the oil filter
side.
aRefit the cylinder head.
Cylinder head tightening procedure
aRefit the cylinder head bolts.
aFit the cylinder head bolts, without tightening them.aTighten to torque and in order the cylinder head
bolts (initial torque) (20 N.m).
aCheck that the cylinder head bolts are tightened to
20 N.m.
aAngle tighten in order the cylinder head bolts (230˚
±± ± ±
6˚).
III - FINAL OPERATION
aConnect the cooling hoses.
aRefit:
-the cooling hose clips using the (Mot. 1448),
-the engine wiring.
aRemove the blanking plugs.
aConnect:
-the petrol inlet union on the injector rail - injectors.
-the coolant temperature sensor connector,
-the throttle body connector ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the injector rail - injector wiring connector,
-the air inlet pressure connector.
-the upstream oxygen sensor connector.
aClip the injection wiring onto the inlet manifold.
aConnect:
-the compressor discharge valve air pipe to the air
filter unit outlet air pipe, WARNING
No regrinding of the cylinder head is permitted.
19598
WARNING
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.
18641

11A-135
TOP AND FRONT OF ENGINE
Camshaft dephaser: Removal - Refitting
K4M
11A
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) .
II - REMOVAL OPERATION
aPosition the (Mot. 1490-01) (1) .
aRemove the camshaft dephaser pulley blanking cov-
er (2) . Special tooling required
Mot. 1490-01For locking and adjusting the
camshaft pulle ys.
103265

11A-136
TOP AND FRONT OF ENGINE
Camshaft dephaser: Removal - Refitting
K4M
11A
aRemove:
-the camshaft dephaser pulley bolt (3) ,
-the exhaust camshaft pulley nut (4) ,
-the (Mot. 1490-01),
-the exhaust camshaft pulley.
-the camshaft dephaser pulley.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Exhaust camshaft
pulley nut.
parts always to be replaced: Camshaft dephaser
sprocket bolt.
parts always to be replaced: Camshaft dephaser
sprocket cap.
aIf fitting a new camshaft dephaser pulley, check that
it is locked by following the procedure described be-
low:
aFit a stud to the camshaft dephaser pulley hub and
tighten it.aPlace the inlet camshaft dephaser in a vice fitted
with jaws.
103264
WARNING
Failure to adhere to the following procedure may
cause the timing belt to be incorrectly timed.
111339

11A-137
TOP AND FRONT OF ENGINE
Camshaft dephaser: Removal - Refitting
K4M
11A
aMechanically lock the camshaft dephaser pulley by
rotating it to the left or right using a tubular hexagon
box spanner.
aCheck that the camshaft dephaser pulley is correctly
locked (the hub does not rotate in relation to the
wheel to the left or right).
aIf the hub rotates in relation to the wheel, the cam-
shaft dephaser pulley is faulty and must be replaced.
aDegrease the end of the inlet camshaft (timing end)
and clean the bores and bearing faces of the cam-
shaft dephaser pulley.
II - REFITTING OPERATION
aRefit:
-the exhaust camshaft pulley.
-the camshaft dephaser pulley.
aFit without tightening:
-the exhaust camshaft pulley bolt,
-the camshaft dephaser pulley nut.
III - FINAL OPERATION
aRefit:
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,
-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).
111340

11A-139
TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting
K9K
11A
aFit the (Mot. 1606) (1) on the cylinder head to lock
the camshaft timing sprocket.
aRemove:
-the camshaft timing sprocket hub nut (2) ,
-the camshaft timing sprocket,
-the cylinder head tool (Mot. 1606).II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the camshaft timing end seal (3) using a flat
screwdriver.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aRemove the camshaft stud using a roller-type stud
removal tool (see ) (TN 6006A, Engine K9K, 10A,
Engine and peripherals).
aClean the gasket faces using SURFACE CLEAN-
ER.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the new camshaft timing end seal using the (Mot.
1632) (see ) (TN 6006A, 10A, Engine and periph-
erals),
-the new camshaft stud using the (Mot. 799-01) and
a roller-type stud removal tool (see ) (TN 6006A,
10A, Engine and peripherals).
118983
117656
WARNING
Do not scratch the aluminium joint faces: any
surface damage to the joint faces may cause
leaks .
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).

11A-140
TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting
K9K
11A
III - FINAL OPERATION.
aRefit:
-the camshaft pulley hub,
-the camshaft pulley hub nut, locking it using the
(Mot. 799-01).
aTorque and angle tighten using a cylinder head
bolt tightening gauge (angular measuring type)
the camshaft hub nut ( 30 Nm + 86˚ ±± ± ±
6˚).
aRefit the camshaft pulley wheel.
aFit the camshaft pulley wheel bolts, without tighten-
ing them.
aRefit:
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,
-the camshaft position sensor (see 13B, Diesel in-
jection, Camshaft position sensor: Removal -
Refitting, page 13B-14) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (MR 412,
42A, Upper front structure),
-the halogen headlights (see Halogen headlight:
Removal - Refitting) (MR 411, 80B, Halogen
headlights),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection),
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (MR 412, 56A, Exterior equipment),-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 412, 56A, Exterior
equipment),
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (MR 411, 85A, Wip-
ers - Washers).
aConnect the battery (see Battery: Removal - Refit-
ting) (see MR 411, 80A, Battery).