charging RENAULT TWINGO 2009 2.G Engine And Peripherals Owner's Manual

12A-15
FUEL MIXTURE
Air filter unit: Removal - Refitting
K9K
12A
REMOVAL
I - REFITTING OPERATION FOR PART
CONCERNED
aSlide the air filter box towards the gearbox side.
aCheck the condition of the air filter box mountings,
replace them if necessary.
aClip:
-the air filter box onto its mountings,
-the air filter air outlet pipe to the air filter.
aTighten the air pipe clip on the air filter outlet.
aRefit the air filter air inlet pipe on the vehicle.
aPosition the turbocharger pressure sensor on the air
filter box.
aRefit the bolt mounting the turbocharger pressure
sensor on the air filter box.
aConnect the connectors:
-of the inlet air temperature sensor,
-of the turbocharging pressure sensor,
-of the flow sensor,
-of the EGR.
aClip on the air filter box harnesses.
aClip the air filter inlet air pipe to the air filter box.
II - FINAL OPERATION.
aRefit the engine cover.Note:
Ensure that the centring lug of the box is fully
inserted in the cylinder head.

12A-50
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K9K
12A
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 cover,
-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 air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the EGR solenoid valve (see 14A, Antipollution,
Exhaust gas recirculation solenoid valve: Re-
moval - Refitting, page 14A-10) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting, page 12B-4) .aRemove:
-the bolts (1) from the lifting eye at the timing end,
-the lifting eye (2) ,
-air inlet metal tube (3) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the rigid exhaust gas recirculation pipe (see
14A, Antipollution, Exhaust gas recirculation rig-
id pipe: Removal - Refitting, page 14A-19) .
aUndo the EGR unit bolts (4) a few turns. Equipment required
cleaning trough
par ts washer
compressed air nozzle
Tightening torquesm
exhaust manifold studs
on the cylinder head9 N.m
exhaust manifold nuts26 N.m
exhaust gas recircula-
tion unit bolts25 N.m
121635
121636

12A-51
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K9K
12A
aRemove:
-the nuts (5) from the exhaust manifold,
-the exhaust manifold,
-the exhaust manifold gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: exhaust manifold
seal.
aAlways replace:
-the air inlet metal tube seals.
aIf the exhaust manifold is being reused, clean it us-
ing a cleaning trough or a parts washer then dry it
using a compressed air nozzle.
aClean the bearing faces using ABRASIVE PADS
on:
-of the cylinder head - exhaust manifold,
-of the exhaust manifold - EGR rigid pipe,
-of the exhaust manifold - turbocharger,
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) and CLEAN CLOTHS to degrease
the bearing faces:
-of the cylinder head - exhaust manifold,
-of the exhaust manifold - EGR rigid pipe,
-of the exhaust manifold - turbocharger,aIf replacing, torque tighten the exhaust manifold
studs on the cylinder head (9 N.m).
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-a new exhaust manifold seal,
-the exhaust manifold.
aTorque tighten in order the exhaust manifold nuts
(26 N.m).
aFit the exhaust gas recirculation unit bolts.
aTorque tighten the exhaust gas recirculation unit
bolts (25 N.m).
aRefit the rigid exhaust gas recirculation pipe (see
14A, Antipollution, Exhaust gas recirculation rig-
id pipe: Removal - Refitting, page 14A-19) .
III - FINAL OPERATION
aRefit:
-a new seal on the air inlet metal tube,
-the air inlet metal tube,
-the lifting eye on the timing end,
-the bolts from the lifting eye, timing end,
-the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting, page 12B-4) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
113561
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).
113561

12A-53
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
D4F, and 780 or 782
12A
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,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the upstream oxygen sensor (see 17B, Petrol in-
jection, Oxygen sensors: Removal - Refitting,
page 17B-13) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting, page 12B-4) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the exhaust manifold nuts (6) .
aRemove:
-the exhaust manifold by undoing the central stud
with a male torx socket and removing the manifold
with a large screwdriver as shown at (7) ,
-the exhaust manifold heat shield bolts,
-the exhaust manifold heat shield,
-the exhaust manifold gasket. Tightening torquesm
exhaust manifold heat
shield bolts18 N.m
exhaust manifold nuts
(initial torque)20 N.m
exhaust manifold nuts30 N.m
IMPORTANT
Wear cut-resistant gloves during the operation.
121200
121771

12A-54
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
D4F, and 780 or 782
12A
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: exhaust manifold
seal.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the exhaust manifold heat shield,
-the exhaust manifold heat shield bolts.
aTorque tighten the exhaust manifold heat shield
bolts (18 N.m).
aRefit:
-a new exhaust manifold gasket,
-the exhaust manifold.
aRefit the exhaust manifold nuts.
aPretighten to torque the exhaust manifold nuts
(initial torque) (20 N.m).
aTorque tighten the exhaust manifold nuts (30
N.m).
III - FINAL OPERATION
aRefit:
-the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting, page 12B-4) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the upstream oxygen sensor (see 17B, Petrol in-
jection, Oxygen sensors: Removal - Refitting,
page 17B-13) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the engine undertray.
aConnect the battery (see ) (80A, Battery).

12B-1
TURBOCHARGING
Turbocharging: Precautions for the repair
D4F or K9K
12B
I - TURBOCHARGER: GENERAL INSTRUCTIONS
For the turbocharging pressure regulator check (see
Fault finding - Tests) (Technical Note 3419A, 12B,
Turbocharging).
II - TURBOCHARGER CIRCUIT DIAGRAMIII - APPLICATION CONDITIONS OF
INSTRUCTIONS
The instructions below must be followed when repla-
cing a turbocharger due to mechanical damage:
-damage to the bearing system,
-broken shaft or turbine wheel,
-compressor wheel rubbing against the turbocharger
casing,
-broken or damaged compressor wheel,
-extensive clogging of the turbine wheel casing (hard
deposits).
FOR THE AIR CIRCUIT:
-Consequences:
•swarf or metal objects in the turbocharger inlet and
outlet pipes,
•oil in the air circuit (collected in the intercooler).
-Risks (after replacing the turbocharger):
•metal objects sucked in by the compressor wheel
(destruction of the turbocharger).
FOR THE LUBRICATION CIRCUIT:
-Consequences:
•swarf found in the engine oil circuit,
•circulation of swarf within the circuit.
-Risks (after replacing the turbocharger):
•premature wear on the bearing system (destruction
of turbocharger).
INSTRUCTIONS:
-Drain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22)
-Replace the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29) .
-Replace the seals and fittings,
-Carry out the following only if the compressor wheel is
broken or rubbing against the turbocharger casing:
•Drain the intercooler, Equipment required
par ts washer
WARNING
The turbocharger pressure regulator rod must not
be adjusted.
112666
(1) Air filter unit
(2) Air flowmeter
(3) Compressor wheel
(4) Intercooler
(5) Inlet distributor
(6) Exhaust manifold
(7) Turbine wheel
(8) Bearing system (bearing +
wheel shaft)
(A) Air filter box air outlet pipe
(B) Turbocharger air outlet pipe
(C) Intercooler air outlet pipe
WARNING
Metal objects may enter the oil and air circuits as a
result of a broken turbocharger.
Failure to follow the INSTRUCTIONS listed will lead
to the turbocharger breaking again.

12B-2
TURBOCHARGING
Turbocharging: Precautions for the repair
D4F or K9K
12B
•Clean the turbocharger air pipes.
IV - AIR CIRCUIT*: INSTRUCTIONS FOLLOWING
MECHANICAL DAMAGE TO THE TURBOCHARGER
Remove the intercooler if fitted to the vehicle (see 12B,
Turbocharging, Intercooler: Removal - Refitting,
page 12B-18) .
Turn the intercooler over and allow the oil inside to
drain out.Check that there are no metal objects inside the air
flowmeter (2) .
Remove:
-the air pipe(between the air filter unit and the turbo-
charger) (A) ,
-the air pipe (B) (between the turbocharger and the in-
tercooler).
For air pipes comprising several components:
-mark (10) the fitting position of each component,
-separate all the components. Note:
When carrying out an oper ation on the air or lubri-
cation circuit, it is necessary to plug the open holes
to prevent any risk of foreign bodies entering the
system.
Note:
(*) These instructions for the air circuit are only to
be followed in the case of:
-broken compressor wheel,
-compressor wheel rubbing against the turbo-
charger casing.
110738
Note:
If the compressor wheel (9) is damaged, metal
objects are ejected inside the air pipes.
112772
112770

12B-3
TURBOCHARGING
Turbocharging: Precautions for the repair
D4F or K9K
12B
One by one, clean the pipes removed with the parts
washer :
-brush as much of the inside of the pipe as possible
(only use brushes with plastic bristles),
-wash plenty of cleaning product from the cleaning sta-
tion through the pipe,
-allow the cleaned pipe to drain by standing it upright,
-ensure the cleaning product has drained out com-
pletely (check areas where liquid may be retained,
e.g. gaiters, resonators etc.).
Dry the pipes one by one using a compressed air spray
gun.
For pipes comprising several components:
-assemble the components, taking note of their correct
fitting position (10) .
Refit:
-the air pipe(between the air filter unit and the turbo-
charger) (A) ,
-the air pipe (B) (between the turbocharger and the in-
tercooler).
Refit the intercooler, if fitted to the vehicle (see 12B,
Turbocharging, Intercooler: Removal - Refitting,
page 12B-18) .V - LUBRICATION CIRCUIT**: INSTRUCTIONS
FOLLOWING MECHANICAL DAMAGE TO THE
TURBOCHARGER
Drain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) .
Replace the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting, page
10A-29) .
Only fill the engine with a suitable oil type (see Engine
oil: Specifications) (Technical Note 6013A, 04A, Lu-
bricants).
VI - GENERAL INSTRUCTIONS TO BE FOLLOWED
WHEN REMOVING A TURBOCHARGER
Always replace:
-the oil supply pipe:
•if the pipe is blocked, even partially (due to scale,
carbonised oil etc.),
•if the pipe is fitted with self-retaining seals.
-the oil return pipe:
•if the pipe is blocked, even partially (due to scale,
carbonised oil etc.),
•if the pipe is fitted with self-retaining seals.
-all seals that have been removed,
-all fittings that have been removed.
When starting the engine:
-do not accelerate,
-allow the engine to run for 1 minute,the time taken for
the oil circuit pressure to increase (until the oil pres-
sure warning light on the instrument panel goes out),
-accelerate several times at no load,
-check the air circuit and the oil circuit for leaks.
112771
Note:
(**) These instructions relating to the lubrication cir-
cuit must always be followed in all cases of
mechanical damage as listed above.
WARNING
Failure to observe the following procedure may lead
to destr uction of the turbocharger.

12B-4
TURBOCHARGING
Turbocharger: Removal - Refitting
K9K
12B
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 cover,
-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 air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the EGR solenoid valve (see 14A, Antipollution,
Exhaust gas recirculation solenoid valve: Re-
moval - Refitting, page 14A-10) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aLoosen the clip (1) of the air outlet pipe on the air fil-
ter unit.
aDisconnect the oil vapour rebreathing pipe (2) .
aRemove:
-the air outlet pipe of the air filter unit (3) ,
-the turbocharger oil pipes (see 12B, Turbocharg-
ing, Turbocharger oil pipe: Removal - Refitting,
page 12B-12) . Equipment required
cleaning trough
par ts washer
compressed air nozzle
Tightening torquesm
studs on the turbo-
charger9 N.m
turbocharger nuts28 N.m
121633

12B-5
TURBOCHARGING
Turbocharger: Removal - Refitting
K9K
12B
aPull the intercooler air inlet pipe clip (4) on the turbo-
charger side.
aDisconnect:
-the air-air intercooler air inlet pipe at the turbo-
charger end,
-the turbocharging pressure regulator pipe (5) .
aRemove:
-the turbocharger nuts (6) ,-the turbocharger,
-the turbocharger seal.
aLoosen the turbocharger air outlet pipe clip (7) from
the turbocharger.
aDisconnect the turbocharger air outlet pipe from the
turbocharger. K9K, and 718
141222
141223
K9K, and 740
121639