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

10A-93
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K9K
10A
II - FINAL OPERATION
aRemove the.
aLubricate the seals using recommended air condi-
tioning oil to make fitting easier.
aRefit:
-the connecting pipes to the compressor,
-the connecting pipe union bolts on the compressor,
-the bolt for the connecting pipe mounting on the
compressor.
aConnect:
-the pressostat connector,
-the hose to the coolant pump inlet pipe using the
tool (Mot. 1448).
aFit:
-the hose clip on the coolant pump inlet pipe using
the tool (Mot. 1448),
-the earth on the front left-hand wing.
aRefit the earth nut on the front left-hand wing.
aClip:
-the engine compartment connection unit relay
plates,
-the fuse holders.
aRefit the fuses.
aConnect the preheating unit connector.
aRefit the earth nut on the front left-hand side mem-
ber.
aFit the engine compartment connection unit.
aRefit the engine compartment connection unit
mountings on the body.
aConnect the black connector.
aClip on the black connector.
aRefit:
-the engine compartment connection unit cover,
-a new clip on the battery mounting to hold the elec-
trical wiring.
aConnect the wiring connectors to the fan assembly.aClip the fan assembly wiring.
aRemove the blanking plugs.
aConnect the high pressure pump inlet pipe.
aClip on the fuel supply pipe.
aConnect the high pressure pump return pipe.
aClip on the fuel return pipe.
aRemove the blanking plugs on the clutch hydraulic
control and on the control pipe.
aConnect the clutch hydraulic control to the gearbox.
aClip:
-the clutch control hydraulic pipe on the gearbox,
-the gearbox controls on the cable sleeve stops,
-the gearbox controls on the gear selectors.
aConnect:
-the hoses to the heater radiator,
-the top hose to the water chamber.
aFit:
-the hose clips on the heater radiator using the tool
(Mot. 1448),
-the clip for the top hose on the water chamber us-
ing the tool (Mot. 1448).
aRefit:
-the front section of the intermediate pipe (see 19B,
Exhaust, Intermediate pipe: Removal - Refit-
ting, page 19B-28) ,
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) . WARNING
To prevent any leaks, check that the seal and the
surface of the pipe are in good condition. The
seal and the surface must be clean and scratch
free.

10A-103
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
-the rubber pad mounting from the suspended en-
gine mounting on the gearbox.
aRemove the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aLift the vehicle to remove the "engine and gearbox"
assembly.
REFITTING
I - REFITTING PREPARATION OPERATION
aFor standard engine replacement (see Standard re-
placement) (Technical Note 6023A, 10A, Engine
and peripherals).
II - REFITTING OPERATION
aPosition the "engine and gearbox" assembly in the
body.
aRefit the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aRefit the rubber pad mounting from the suspended
engine mounting on the gearbox.
aTorque tighten the rubber pad mounting bolts for
the suspended engine mounting on the gearbox
(21 N.m).
aRefit the suspended engine mounting rubber pad.
aTorque tighten:
-the bolts of the suspended mounting rubber
pad (62 N.m),
-the suspended engine mounting shaft nut (62
N.m).
III - FINAL OPERATION
aRemove the.
aRemove the blanking plugs.
aConnect:
-the union of the brake servo vacuum pipe,
-the « compressor - condenser » connecting pipe,-the « compressor - intermediate pipe » connecting
pipe,
-the pressure sensor connector,
aConnect the hose on the coolant pump inlet pipe.
aFit the hose clip on the coolant pump inlet pipe using
the (Mot. 1448).
aRefit the earth nuts.
aClip:
-the relay plates on the engine compartment con-
nection unit,
-the fuse holders.
aConnect the fuses.
aRefit the engine compartment connection unit on the
body.
aConnect the connector to the engine compartment
connection unit.
aRefit the engine compartment connection unit cover.
aClip:
-the wiring on the engine cooling fan assembly,
-the cooling radiator top and bottom hoses on the
engine cooling fan assembly.
aConnect:
-the engine cooling fan assembly resistor connec-
tor,
-the engine cooling fan assembly connector.
aRemove the blanking plug from the fuel supply pipe
opening and the injector rail fuel opening.
aReconnect the fuel supply pipe.
aClip the fuel supply pipe in place.
aConnect:
-the fuel vapour absorber bleed solenoid valve con-
nector,
-the fuel vapour absorber bleed solenoid valve pipe.
aFit the gearbox control cables.
aClip the manual gearbox control cables onto:
-the gear selectors,
-the cable sleeve stops.
aRemove the blanking plug from the hydraulic clutch
control pipe opening and the opening of the clutch
thrust bearing.
aConnect the hydraulic clutch control pipe.
aClip the hydraulic clutch control pipe on the gearbox. Note:
Check no component obstructs the movement of
the body around the engine - gearbox assembly.

11A-1
TOP AND FRONT OF ENGINE
Pressure at end of compression: Check
K4M
11A
CHECK
I - PREPARATION OPERATION FOR CHECK
aRemove:
-the coils (see 17A, Ignition, Coils: Removal - Re-
fitting, page 17A-1) ,
-the spark plugs (see 17A, Ignition, Plugs: Re-
moval - Refitting, page 17A-12) .
aDisconnect the injector wiring connector (1) .aConnect a petrol compression gauge (2) .
aPut the vehicle under the starting conditions by posi-
tioning the gear lever in neutral.
II - TEST OPERATION
aActivate the starter until the needle of the petrol
compression gauge stabilises.
aMeasure the cylinder compressions, cylinder by cyl-
inder.
aFully depress the accelerator pedal in order to open
the throttle valve during the compression measure-
ments.
III - FINAL OPERATION
aDisconnect the petrol compression gauge.
aConnect the injector wiring connector.
aRefit:
-the spark plugs (see 17A, Ignition, Plugs: Re-
moval - Refitting, page 17A-12) ,
-the coils (see 17A, Ignition, Coils: Removal - Re-
fitting, page 17A-1) . Equipment required
petrol compression gauge
132371
132338
Note:
It is necessar y to wait for at least 10 seconds
before starting the engine each time (the starter
will not run due to its ther mal protection).

11A-2
TOP AND FRONT OF ENGINE
Pressure at end of compression: Check
D4F
11A
CHECK
I - PREPARATION OPERATION FOR CHECK
aRemove the plugs (see 17A, Ignition, Plugs: Re-
moval - Refitting, page 17A-12) .
aConnect a petrol compression gauge (1) .
aRun command with Diagnostic tool :
-RZ009: VEHICLE FUNCTION PROGRAMMING,
-VP036: FUEL SUPPLY INHIBITION.
aPut the vehicle under the starting conditions by posi-
tioning the gear lever in neutral.II - TEST OPERATION
aActivate the starter until the needle of the petrol
compression gauge stabilises.
aMeasure the cylinder compressions, cylinder by cyl-
inder.
aFully depress the accelerator pedal in order to open
the throttle valve during the compression measure-
ments.
III - FINAL OPERATION
aDisconnect the petrol compression gauge.
aRefit the plugs (see 17A, Ignition, Plugs: Removal
- Refitting, page 17A-12) .
aRun command VP037: "STOP INHIBIT FUEL SUP-
PLY" using the Diagnostic tool.
aStart the engine. Equipment required
petrol compression gauge
Diagnostic tool
Note:
Use a petrol compression gauge compatible with
the special tools.
The petrol compression gauge must be equipped
with a universal end piece (rubber), or a gaz 1/4
thread bolt.
132699
Note:
It is necessar y to wait for at least 10 seconds
before starting the engine each time (the starter
will not run due to its ther mal protection).
Note:
If the engine does not start, run command
VP037: STOP FUEL SUPPLY INHIBITION using
the Diagnostic tool or switch off the ignition and
wait 1 min before starting the engine again.

11A-3
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
D4F, and 772, and STANDARD HEATING – D7F, and STANDARD HEATING
11A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
aUndo the alternator bolts (1) .
aSwing the alternator towards the engine.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the accessories belt.
REFITTING
I - REFITTING PREPARATION OPERATION
aUse a brush to remove any deposits from the crank-
shaft accessories pulley V grooves.
aparts always to be replaced: Accessories belt.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the accessories belt. Special tooling required
Mot. 1715Belt tension checking tool
(frequency indicator).
Mot. 1505Belt tension setting tool (fre-
quency meter)
Tightening torquesm
alter nator lower bolt50 N.m
alter nator upper bolt25 N.m
120305
WARNING
Only use brushes with plastic or non-corrosive
metal (br ass) bristles.

11A-4
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
D4F, and 772, and STANDARD HEATING – D7F, and STANDARD HEATING
11A
Accessories belt tensioning process
aTension the accessories belt by swinging the alter-
nator towards the front using a lever.
aSet the accessories belt tension using the (Mot.
1715) or the (Mot. 1505) to a value of 244 Hz ±± ± ±
5.
aTorque tighten:
-the alternator lower bolt (50 N.m),
-the alternator upper bolt (25 N.m).
aTurn the engine three revolutions clockwise (timing
end) to position the accessories belt correctly.
aCheck the accessories belt tension using the (Mot.
1715) or the (Mot. 1505).
aIf the accessories belt tension is outside permitted
tolerance values, readjust the tension.
III - FINAL OPERATION
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
120525

11A-6
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
K9K, and AIR CONDITIONING
11A
aRemove the accessories belt, passing it over its slot
between the RH side member and the crankshaft
accessories and air conditioning compressor pul-
leys.
aDiscard the accessories belt
2 - Removing the tensioning roller
a
aRaise the engine using the (Mot. 1672).
aDisconnect the connector on the alternator.
aRemove the nut from the alternator harness.
aMove the alternator harness to one side.
aRemove the alternator upper bolt.
aLoosen the alternator lower bolt.
aRemove:
-the alternator with its lower bolt fitted,
-the tensioning roller bolt,
-the tensioning roller.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
1 - Refit the tensioning roller
aRefit:
-the new tensioning roller,
-the new tensioning roller bolt.
aTorque tighten the tensioning roller bolt (40 Nm).
aRefit:
-the alternator with its lower bolt fitted,
-the alternator upper bolt.
aTorque tighten the alternator bolts (25 Nm).
aFit the alternator harness.aRefit the nut to the alternator wiring harness.
aAttach the connector to the alternator.
2 - Refit the accessories belt
aLower the engine using the (Mot. 1672).
aPartially refit the new accessories belt, passing it
over its slot between the RH side member and the
crankshaft accessories and air conditioning com-
pressor pulleys.
aRaise the engine using the (Mot. 1672).
aFit the belt on the crankshaft accessories, air condi-
tioning compressor and tensioning roller pulleys.
aSwing the accessories belt auto tensioner clockwise
using a ratchet, an extension and a 16 mm socket
aFit the belt on the alternator pulley, passing it over its
slot between the headlight carrier panel and the al-
ternator pulley.
aGently release the tensioning roller.
aCheck that the accessories belt is correctly mounted
on the crankshaft accessories, air conditioning com-
pressor and alternator pulleys.
aTurn the engine two revolutions.
aCheck that the accessories belt is correctly mounted
on the crankshaft accessories, air conditioning com-
pressor, alternator and tensioning roller pulleys.
aAdjust the engine using the (Mot. 1672) to restore
the engine's approximate original position.
II - FINAL OPERATION.
aRefit:
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) .
-the air conditioning pipe clip onto the right-hand
headlight carrier panel, Note:
Shift the engine forwards or backwards slightly
by hand if necessary to facilitate removing the
accessories belt.
Note:
The tensioning roller must be replaced every
time the accessories belt is replaced.
Note:
Shift the engine forwards or backwards slightly
by hand if necessary, to facilitate refitting the
accessor ies belt.
Note:
Shift the engine forwards slightly by hand to facil-
itate setting up the tools.

11A-8
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
D4F, and 772 or 780 or 782, and AIR CONDITIONING – D7F, and AIR CONDITIONING
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 front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front right-hand wheel arch liner clips,
-the front right-hand wheel arch liner bolts,
aRemove the lower section of the front right-hand
wheel arch liner.II - OPERATION FOR REMOVAL OF PART
CONCERNED
a
aRemove the accessories belt tensioning roller pro-
tector.
aUndo the accessories belt tensioning roller bolt.
aRemove:
-the accessories belt,
-the accessories belt tensioning roller bolt,
-the accessories belt tension wheel.
REFITTING
I - REFITTING PREPARATION OPERATION
aUse a brush to remove any deposits from the crank-
shaft pulley V-grooves.
aparts always to be replaced: Accessories belt.
aparts always to be replaced: Accessories belt
tensioning roller. Special tooling required
Mot. 1715Belt tension checking tool
(frequency indicator).
Mot. 1505Belt tension setting tool (fre-
quency meter)
Equipment required
open-ended spanner
Tightening torquesm
tensioning roller bolt44 N.m
120775
109766
IMPORTANT
Wear cut-resistant gloves during the operation.
WARNING
Only use brushes with plastic or non-corrosive
metal (br ass) bristles.

11A-9
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
D4F, and 772 or 780 or 782, and AIR CONDITIONING – D7F, and AIR CONDITIONING
11A
aparts always to be replaced: Accessories ten-
sioning roller bolt (to be replaced by the hexagonal
head bolt, part no. 77 03 101 075).
aRefit:
-the new accessories belt tensioning roller,
-the accessories belt tensioning roller hexagonal-
head bolt
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the accessories belt.
aTension the accessories belt by turning the tension-
ing roller anti-clockwise using an open-jawed span-
ner.
aAdjust the accessories belt tension using the (Mot.
1715) or (Mot. 1505).aFit the accessories belt tensioning roller bolt without
tightening it, maintaining the accessories belt ten-
sion at a setting value of 274 Hz ±± ± ±
4.
aTorque tighten the tensioning roller bolt (44 N.m)
using a torque wrench fitted with a open-ended
spanner, maintaining the accessories belt tension
at the adjustment value of 277 Hz ±± ± ±
5 using an open-
jawed spanner.
aTurn the engine three revolutions clockwise (timing
end) to position the accessories belt correctly.
aCheck the accessories belt tension using the (Mot.
1715) or (Mot. 1505).
aIf the accessory belt tension is outside permitted tol-
erance values, readjust it.
aRefit the accessories belt tension wheel protector.
III - FINAL OPERATION
aFit the lower section of the front right-hand wheel
arch liner.
aRefit:
-the front right-hand wheel arch liner bolts,
-the front right-hand wheel arch liner clips,
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
112339
120524

11A-12
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
K9K, and STANDARD HEATING
11A
aCheck that the accessories belt is correctly mounted
on the crankshaft accessories, air conditioning com-
pressor and alternator pulleys.
aTurn the engine two revolutions.
aCheck that the accessories belt is correctly fitted on
the crankshaft accessories, air conditioning com-
pressor substitute, alternator and tensioning roller
pulleys.
II - FINAL OPERATION.
aRefit the front upper cross member (see Front up-
per cross member: Removal - Refitting) (MR 412,
42A, Upper front structure).
aFit the « cable - bonnet catch » assembly.
aRefit the bonnet catch nuts.
aClip the following onto the front upper cross mem-
ber:
-the air filter inlet air pipe,
-the expansion bottle.
aRefit:
-the air filter inlet air pipe bolt onto the front upper
cross member,
-the expansion bottle bolt onto the front upper cross
member,
-the cooling radiator retaining bracket bolt onto the
front upper cross member.
-the left-hand and right-hand headlights (see Halo-
gen headlight: Removal - Refitting) (MR 411,
80B, 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),
aConnect the battery (see ) (MR 411, 80A, Battery).
aAdjust the headlights (see Halogen headlight: Ad-
justment) (MR 411, 80B, Headlights).