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

19A-43
COOLING
Water chamber: Removal - Refitting
K9K
19A
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aPull the intercooler air inlet pipe clip (1) at the turbo-
charger end.
aDisconnect the intercooler air inlet pipe (2) at the tur-
bocharger end.
aRemove the nut (3) from the intercooler air inlet pipe
at the turbocharger end.
aMove aside the intercooler air inlet pipe (2) at the tur-
bocharger end.
aRemove the nut (4) from the intercooler air outlet
pipe at the damper valve end.
aDisconnect the turbocharging pressure regulator
vacuum pipe (5) .
aUnclip:
-the turbocharging pressure regulator vacuum pipe
at (6) ,
-the brake servo vacuum pipe at (7) .
aDisconnect the brake servo vacuum pipe (8) .
aLoosen the clamp (9) for the air-air intercooler air
outlet pipe at the damper valve end.
aDisconnect the intercooler air outlet pipe (10) at the
damper valve end.
aMove aside the intercooler air outlet pipe (10) at the
damper valve end. K9K, and 718
141222
141213
141217

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-50
COOLING
Water chamber: Removal - Refitting
K4M
19A
II - REFITTING OPERATION
aRefit the coolant outlet unit with a new seal.
aPretighten in order and to torque the water cham-
ber bolts (initial torque) (4 N.m).
aTorque tighten in order the water chamber bolts
(12 N.m).
III - FINAL OPERATION
aClip the wiring onto the water chamber.
aFit the engine wiring channel.
aRefit:
-the coolant temperature sensor (see 19A, Cool-
ing, Coolant temperature sensor: Removal - Re-
fitting, page 19A-66) ,
-the heater matrix hose bracket.
aTorque tighten the heater matrix hose bracket bolt
(10 N.m).
aConnect to the coolant outlet unit:
-the heater matrix hose,
-the cooling radiator top hose.
aUsing the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) fit:
-the heater matrix hose clip,
-the cooling radiator top hose clip.
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) .
aRefit the engine undertray.
128456

19A-66
COOLING
Coolant temperature sensor: Removal - Refitting
D4F or D7F
19A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aParts always to be replaced :
-coolant temperature sensor seal.
aConsumable (see Vehicle: Parts and consuma-
bles for the repair) :
-COOLANT.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the coolant temperature sensor connec-
tor (1) .
aRemove the coolant temperature sensor.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the new coolant temperature sensor seal,
-the coolant temperature sensor.
aTighten the coolant temperature sensor.
aConnect the coolant temperature sensor connector.
II - FINAL OPERATION
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
aTop up the coolant fluid level.
aBleed the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) . D4F
114326
D4F

19A-69
COOLING
Coolant temperature sensor: Removal - Refitting
D4F, and 780
19A
a
Remove the turbocharger air outlet pipe bolt (3) from
the throttle valve.
aDetach the turbocharger air outlet pipe from the tur-
bocharger in the direction of the arrow (4) .aDisconnect the turbocharger air outlet pipe from the
turbocharger.
aRemove the throttle valve (see 12A, Fuel mixture,
Throttle valve: Removal - Refitting, page 12A-20)
.
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
II - REMOVAL OPERATION FOR PART
CONCERNED
aDisconnect the coolant temperature sensor connec-
tor (6) .
aRemove the coolant temperature sensor.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aAlways replace the coolant temperature sensor O-
ring.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the new coolant temperature sensor O-ring,
122833
122673
Note:
If the tightening clip (1) is removed from the tur-
bocharger air outlet pipe, the flexible rubber pipe
(2) and tightening clip (1) must be replaced.
Note:
If the clip (5) is removed from the heat resistant
protector, the latter must be replaced.
114326

19A-70
COOLING
Coolant temperature sensor: Removal - Refitting
D4F, and 780
19A
-the coolant temperature sensor.
aTorque tighten the coolant temperature sensor
(23 Nm).
aConnect the coolant temperature sensor connector.
III - FINAL OPERATION
aRefit the throttle valve (see 12A, Fuel mixture,
Throttle valve: Removal - Refitting, page 12A-20)
.
aPush the turbocharger air outlet pipe clip in the di-
rection of the arrow (7) .
aConnect the turbocharger air outlet pipe onto the tur-
bocharger.
aRefit the turbocharger air outlet pipe bolt on the
throttle valve.
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) .
122666

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

19A-72
COOLING
Coolant temperature sensor: Removal - Refitting
K4M
19A
III - FINAL OPERATION
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
aPerform the following operations:
-top up the coolant level,
-bleed the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .

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-14
EXHAUST
Catalytic converter: Removal - Refitting
K9K
19B
aIf they are replaced, torque tighten the catalytic
converter studs on the turbocharger (9 Nm ).
II - REFITTING OPERATION FOR PART
CONCERNED
aFrom underneath the vehicle, fit:
-the catalytic converter on the turbocharger fitted
with a new seal between the catalytic converter
and the turbocharger,
-one of the catalytic converter nuts on the turbo-
charger.
aIn order, fit (without tightening):
-the catalytic converter upstream strut bolts on the
engine,
-the catalytic converter downstream strut bolt and
nut on the gearbox,
-the catalytic converter upstream strut bolts on the
catalytic converter,
-the catalytic converter downstream strut bolt on the
catalytic converter,
-the catalytic converter nuts on the turbocharger,
aTorque tighten and in order:
-the catalytic converter nuts on the turbocharger
(26 Nm),
-the catalytic converter upstream strut bolts on
the engine (44 Nm),
-the catalytic converter downstream strut bolts
on the gearbox (21 Nm),
-the catalytic converter downstream strut nut on
the gearbox (21 Nm),
-the catalytic converter upstream strut bolts on
the catalytic converter (26 Nm),
-the catalytic converter downstream strut bolt
on the catalytic converter (21 Nm).
aFit in order:
-a new exhaust system sealing ring on the catalytic
converter,
-the exhaust pipe on the catalytic converter,
-the exhaust pipe springs and bolts on the catalytic
converter.aTorque tighten the exhaust pipe bolts on the cata-
lytic converter (21 Nm).
aCheck the following and deal with if necessary:
-that there is no contact with the underbody,
-the presence and correct positioning of all the ex-
haust pipe heat shields.
III - FINAL OPERATION.
aRefit:
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) ,
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the scoop under the scuttle panel grille ( (see
Scoop under the scuttle panel grille: Removal -
Refitting) ),
-the scuttle panel grille ( (see Scuttle panel grille:
Removal - Refitting) ),
-the windscreen wiper arms ( (see Windscreen
wiper arm: Removal - Refitting) ).
aConnect the battery ( (see Battery: Removal - Re-
fitting) ).
aStart the engine.
aCheck that there are no leaks and deal with them if
necessary. Note:
Check that there is no contact between the cata-
lytic conver ter and the turbocharger oil return
pipe during the entire catalytic converter tighten-
ing operation.