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

11A-130
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
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 (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection).
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aRemove:
-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 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) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the turbocharger oil pipes (see 12B, Turbocharg-
ing, Turbocharger oil pipe: Removal - Refitting,
page 12B-12) .
aUnclip the wiring from the turbocharger coolant rigid
pipe bracket.
aSeparate the clips (1) on the turbocharger cooling
hoses using the tool (Mot. 1448).
aDisconnect the turbocharger cooling hoses.
aRemove:
-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 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) . Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
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.
121773

11A-131
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
aRemove the bolts (2) on the intercooler outlet air
pipe.
aMove the intercooler outlet air pipe away from the
throttle valve.
aUndo the compressor discharge valve air pipe clip
(3) .
aDisconnect:
-the turbocharging solenoid valve connector to the
turbocharger,
-the compressor discharge valve air pipe from the
air filter unit outlet air pipe.aUnclip the injection wiring from the inlet manifold.
aDisconnect:
-the upstream oxygen sensor connector (4) .
-the air inlet pressure connector (5) ,
-the injector rail - injector wiring connector (6) ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the throttle body connector ,
-the coolant temperature sensor connector.
aDisconnect the petrol supply union on the injector
rail - injector.
aPlug the openings.
aMove aside the engine wiring.
122390121765
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to r un.
IMPORTANT
Dur ing 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.

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-134
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
-the turbocharging solenoid valve connector to the
turbocharger.
aTighten the compressor discharge valve air pipe
clip.
aPosition the intercooler outlet air pipe on the throttle
valve.
aRefit:
-the intercooler air outlet pipe bolts,
-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 right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) .
aConnect the turbocharger cooling hoses.
aFit the turbocharger cooling hose clips using the tool
(Mot. 1448).
aClip the wiring onto the turbocharger coolant rigid
pipe bracket.
aRefit:
-the turbocharger oil pipes (see 12B, Turbocharg-
ing, Turbocharger oil pipe: Removal - Refitting,
page 12B-12) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) ,
-the ignition coil (see 17A, Ignition, Coils: Remov-
al - Refitting, page 17A-1) ,
-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) .
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) .
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).aRefit:
-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).

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-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-141
TOP AND FRONT OF ENGINE
Camshaft seal, timing end: 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) ,
-the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-135) .
II - REMOVAL OPERATION
a
aCompletely unscrew the nut (1) and the bolt (Mot.
1577) of the (2) . Special tooling required
Mot. 1577Lip seal e xtractor (shaft diam-
eter 28 mm to 42 mm).
Mot. 1632Tool for fitting camshaft PTFE
seal
105257
Note:
The camshaft seal is removed using the (Mot.
1577).

11A-145
TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting
K4M
11A
aFit the cover (13) and the collar nut (14) of the (Mot.
1632).
aScrew on the collar nut until the cover touches the
cylinder head.
aRemove:
-the collar nut from the (Mot. 1632),
-the cover from the (Mot. 1632),
-the stud from the (Mot. 1632).
III - FINAL OPERATION
aRefit:
-the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-135) ,
-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).
126222

11A-147
TOP AND FRONT OF ENGINE
Oil decanter: Removal - Refitting
K4M
11A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see ) (80A, Battery).
aRemove:
-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 inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the bolts (1) from the oil separator,
-the oil decanter,
-the oil separator seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Oil decanter seal.
parts always to be replaced: oil decanter bolt.
aUse SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to clean:
-the oil separator joint face if it is to be re-used,
-the rocker cover joint face.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) to degrease:
-the oil separator joint face if it is to be re-used,
-the rocker cover joint face. Tightening torquesm
oil separator bolts10 N.m
101820
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
When cleaning par ts, it is essential that the parts
do not impact on each other, otherwise their mat-
ing faces may be damaged and therefore their
adjustments may be altered, which could dam-
age the engine.
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).

11A-148
TOP AND FRONT OF ENGINE
Oil decanter: Removal - Refitting
K4M
11A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-a new seal on the oil separator,
-the oil decanter.
aTighten to torque and in order the oil separator
bolts (10 N.m).
III - FINAL OPERATION
aRefit:
-the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-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).
aConnect the battery (see ) (80A, Battery).
101820