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

10A-78
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
D4F or D7F
10A
aDrain the coolant circuit (see Refrigerant circuit:
Draining - Filling) .
aRemove:
-the air conditioning pipe bolts on the compressor,
-the air conditioning pipe bolt on the dehydrator res-
ervoir.
aDisconnect the air conditioning pressostat connec-
tor.
a
aDisconnect the fuel supply pipe union.
aInsert the blanking plugs.
aUnclip the fuel pipe on the upper timing cover.aSet the wheels straight ahead.
aPosition the flywheel immobiliser.
aRemove the cover from the universal joint (do not
keep).
aRemove the universal joint bolt (do not keep).
aRemove the universal joint from the steering box.
aDetach the electrical wiring on the cross member.
aLoosen the tie rod lower bolts.
aRemove:
-the tie rod upper bolts.
-the track rod end nuts,
-the track rod ends using the (Tav. 476),
-the lower guide pin bolts,
-the brake pads,
-the calliper mounting bolts,
-the brake callipers, and attach them to the suspen-
sion springs,
-the ABS sensor bolts (if fitted to the vehicle),
-the ABS sensors,
-the shock absorber base lower bolts, AIR CONDITIONING
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which
are open to the air.
IMPORTANT
During this operation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting
the union.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
119544

10A-83
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
D4F or D7F
10A
aTorque tighten:
-the front subframe bolts (62 N.m),
-the rear subframe bolts (105 N.m),
-the subframe rear tie rod inner bolts (21 N.m),
-the subframe rear tie rod outer bolts (90 N.m),
-the engine tie-bar bolts on the gearbox (105
N.m),
-the engine tie-bar bolt on the subframe (105
N.m).
aRefit the control cables onto the gearbox.
aRemove the blanking plugs from the openings.
aClip the clutch pipe onto the gearbox.
aConnect the clutch slave cylinder.
aRemove the hose clamp (Ms. 583).
aBleed the clutch circuit (see Clutch circuit: Bleed) .
aRefit the gear control linkage.
aAttach the gear control linkage to:
-the gear lever,
-the control lever on the gearbox.
aRefit:
-the heat shield,
-the heat shield bolts.
aRefit the clutch control cable on the manual gearbox.
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .aRefit the exhaust downpipe.
aFit the clip.
aTighten the intermediate pipe clip.
aRefit the exhaust downpipe bolts.
aTorque tighten the exhaust downpipe bolts (9
N.m).
aRefit:
-the shock absorber base lower bolts,
-the ABS sensors,
-the ABS sensor bolts (if fitted to the vehicle),
-the brake callipers,
-the calliper mounting bolts,
-the brake pads,
-the lower guide pin bolts,
-track rod ends,
-the track rod end nuts,
-the tie rod upper bolts.
aTorque tighten:
-the shock absorber base lower bolts (105 N.m ),
-the calliper mounting bolts (105 N.m),
-the lower guide pin bolts (34 N.m),
-the track rod end nuts (37 N.m),
-the tie rod upper bolts (21 N.m),
-the tie rod lower bolts (62 N.m).
aClip the electrical wiring on to the cross member.
aFit the steering box universal joint.
aRefit the universal joint bolt.
aTorque tighten the universal joint (24 N.m).
aRemove the flywheel immobiliser.
aClip the fuel pipe on to the upper timing cover.
aConnect the fuel supply pipe union.
aConnect the air conditioning pressostat connector. JH3
JB1 or JH1
D4F, and 772 – D7F
D4F, and 780 or 782
AIR CONDITIONING

10A-85
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
D4F or D7F
10A
aClip the fuse holder onto the engine compartment
connection unit.
aRefit:
-the engine compartment connection unit bolts,
-the engine compartment connection unit supply
nut.
aConnect:
-the fuses,
-the connector.
aRefit:
-the engine compartment connection unit cover,
-the engine compartment connection unit cover
bolts.
aRefit:
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion).
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the computer mounting,
-the computer mounting nuts,
-the computer mounting bolts,
-the injection computer (see 17B, Petrol injection,
Petrol injection computer: Removal - Refitting,
page 17B-20) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the battery (see ) (80A, Battery).

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-96
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
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) .
aRemove the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aRemove:
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the engine undertray,
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),-the cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, page 19A-9) ,
-the engine, if necessary (see 10A, Engine and
cylinder block assembly, Engine oil: Draining -
Refilling, page 10A-22) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aAttach the « engine cooling radiator - condenser »
assembly to the front upper cross member.
aRemove:
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the differential output seal (see Differential output
seal: Removal - Refitting) (21A, Manual gear-
box).
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) . Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Equipment required
refrigerant charging station
Tightening torquesm
rubber pad mounting
bolts for the suspended
engine mounting on the
gearbox21 N.m
bolts of the suspended
mounting r ubber pad62 N.m
suspended engine
mounting shaft nut62 N.m

10A-107
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
D4F – D7F – K9K
10A
REMOVAL
I - REFITTING PREPARATIONS OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).
aRemove:
-the gearbox (see Manual gearbox: Removal - Re-
fitting) ,
-the clutch plate and pressure plate (see Pressure
plate - Disc: Removal - Refitting) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aLock the engine using tool (Mot. 582-01) (1) .
aRemove:
-the flywheel bolts,
-the flywheel,
-tool (Mot. 582-01). Special tooling required
Mot. 582-01Flywheel locking tool.
Tightening torquesm
D4F, D7F flywheel bolts18 Nm + 110˚ ±± ± ±
10˚
K9K flywheel bolts70 Nm
109158

10A-108
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
D4F – D7F – K9K
10A
REFITTING
I - REFITTING PREPARATIONS OPERATION
aDo not remove the flywheel drive plate bolts (2) .
aOn the crankshaft, clean the flywheel bolt threading.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRefit the spacer (3) observing the direction of fitting
for the chamfer (4) on the flywheel side.
aAlways replace the flywheel mounting bolts with new
ones.
aRefit:
-the flywheel,
-the new flywheel bolts.
aLock the engine using tool (Mot. 582-01). K9K
23325
K9K
101356

10A-109
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
D4F – D7F – K9K
10A
Tightening order
aObserve the tightening order.
aTorque and angle tighten, in order, the D4F, D7F fly-
wheel bolts (18 Nm + 110˚ ±± ± ±
10˚).
aTighten to torque and in order the K9K flywheel
bolts (70 Nm).
aRemove tool (Mot. 582-01).
III - FINAL OPERATION.
aRefit:
-the clutch plate and pressure plate (see Pressure
plate - Disc: Removal - Refitting) ,
-the gearbox (see Manual gearbox: Removal - Re-
fitting) .
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).
23326
D4F – D7F
K9K

10A-110
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
K4M
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-the engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).aRemove:
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the « engine - gearbox » assembly (see 10A, En-
gine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) (21A, Manual gearbox),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) ,
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch).
II - REMOVAL OPERATION
aRemove:
-the flywheel bolts,
-the (Mot. 1677) (1) , Special tooling required
Mot. 1677Flywheel locking tool.
Equipment required
refrigerant charging station
Tightening torquesm
flywheel bolts70 N.m
109158

10A-111
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
K4M
10A
-the flywheel.
REFITTING
I - REFITTING PREPARATION OPERATION
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the flywheel bearing face if reusing,
-the crankshaft bearing face.
aAlways replace the flywheel bolts.
II - REFITTING OPERATION
aFit the flywheel.
aFit the new flywheel bolts without tightening them.
aPosition the (Mot. 1677).
aTighten to torque and in order the flywheel bolts
(70 N.m).
III - FINAL OPERATION
aRefit:
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) (21A, Manual gearbox).-the « engine and gearbox » assembly (see 10A,
Engine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) ,
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-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 front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aPerform the following operations:
-fill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) ,
-fill the gearbox (see Manual gearbox oils: Drain-
ing - Filling) (21A, Manual gearbox).
-fill the refrigerant circuit using a refrigerant charg-
ing station (see Refrigerant circuit: Draining -
Filling) (62A, Air conditioning).
aRefit the engine undertray.
109158