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

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-55
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K4M
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 Battery: Removal - Re-
fitting) (80A, Battery).
aRemove:
-the engine undertray,
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-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).
aDrain the gearbox (see Manual gearbox oils:
Draining - Filling) (21A, Manual gearbox).aRemove:
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the upstream expansion chamber (see 19B, Ex-
haust, Expansion chamber: Removal - Refit-
ting, page 19B-23) .
aRemove:
-the bolts (1) from the driveshaft relay bearing,
-the driveshaft relay bearing. Tightening torquesm
exhaust manifold studs9 N.m
heat shield bolts12 N.m
upstream and down-
stream oxygen sensors44 N.m
strut mounting bolt on
the cylinder block75 N.m
upstream strut bolt (ini-
tial torque)14 N.m
exhaust manifold nuts26 N.m
upstream and down-
streamstrut bolts44
N.m
upstream strut bolts44 N.m
driveshaft relay bearing
bolts21 N.m
IMPORTANT
Wear cut-resistant gloves during the operation.
131770

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-8
TURBOCHARGING
Turbocharger: Removal - Refitting
D4F, and 780 or 782
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 Battery: Removal - Re-
fitting) (80A, Battery).
aRemove the engine undertray.
aDrain the manual gearbox (see Manual gearbox
oils: Draining - Filling) (21A, Manual gearbox).
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 lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the turbocharger oil return pipe (see 12B,
Turbocharging, Turbocharger oil pipe: Removal
- Refitting, page 12B-12) .
aFit the tools (Ms. 583) onto the turbocharger cooling
hoses (6) .
aRemove the turbocharger cooling hose clips using
the tool (Mot. 1448).
aDisconnect the turbocharger cooling hoses.
aRemove the turbocharger cooling pipe strut bolt (7) .
aRemove the turbocharger oil supply pipe (see 12B,
Turbocharging, Turbocharger oil pipe: Removal
- Refitting, page 12B-12) . Special tooling required
Ms. 583Pipe clamps .
Mot. 1448Remote operation pliers for
hose clips .
Tightening torquesm
turbocharger nuts21 N.m
turbocharger cooling
pipe hollow bolts30 N.m
turbocharger cooling
pipe bracket bolts10 N.m
IMPORTANT
Wear cut-resistant gloves during the operation.121773

12B-12
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting
D4F, and 780 or 782
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 Battery: Removal - Re-
fitting) (80A, Battery).
aRemove:
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the air filter box strut bolt,
-the air filter box strut,
-the upstream oxygen sensor (see 17B, Petrol in-
jection, Oxygen sensors: Removal - Refitting,
page 17B-13) . Tightening torquesm
turbocharger oil return
pipe bolts10 N.m
turbocharger oil supply
pipe bolt on the cylinder
block19 N.m
turbocharger oil supply
pipe bolt on the turbo-
charger19 N.m
turbocharger oil supply
pipe bolt10 N.m

12B-16
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting
C44, and K9K
12B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the front engine cover.
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
1 - Turbocharger oil supply pipe
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 air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the exhaust gas recirculation solenoid valve (see
14A, Antipollution, Exhaust gas recirculation
solenoid valve: Removal - Refitting, page 14A-
10) .
2 - turbocharger oil return pipe
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
1 - Turbocharger oil supply pipe
aRemove the bolt (1) of the turbocharger oil supply
pipe from the turbocharger.
aUndo the nut (2) of the turbocharger oil supply pipe
on the cylinder head.
aRemove the nut of the turbocharger oil supply pipe
on the cylinder head.
aRemove the turbocharger oil supply pipe. Special tooling required
Mot. 1746Offset wrench for tightening
High Pressure pump pipes.
Tightening torquesm
nut of the oil supply pipe
on the cylinder head35 Nm
bolt of the turbocharger
oil supply pipe on the
turbocharger14 Nm
turbocharger oil return
pipe bolts12 N.m
127900
127898

12B-18
TURBOCHARGING
Intercooler: Removal - Refitting
D4F, and 780 or 782 – K9K, and 718
12B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-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).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the intercooler bolts (1) .
aLoosen the clip on the intercooler air outlet pipe (2) .
aDisconnect the intercooler air outlet pipe.
aUnclip the turbocharger air outlet pipe (3) .
aDisconnect the turbocharger air outlet pipe.
aRemove:
-the intercooler,
-the air deflector clips,
-the air deflector,
-the metal mounting.
REFITTING
I - REFITTING PREPARATION OPERATION
aCheck that the intercooler is not full of oil. In this
case, clean it with cleaning agent and let it dry (see
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products).
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the metal mounting,
-the air deflector,
-the air deflector clips,
-the intercooler.
aConnect the turbocharger air outlet pipe.
aClip on the turbocharger air outlet pipe.
aConnect the intercooler air outlet pipe.
aTighten the clip on the intercooler outlet pipe.
aRefit the intercooler bolts.
III - FINAL OPERATION
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).
122830

13A-2
FUEL SUPPLY
Manual priming pump: Removal - Refitting
K9K
13A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aCONSUMABLES:
-cleaning cloths.
a
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove the front engine cover.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDetach the fuel pipe from the body.
aDisconnect the electric diesel fuel heater fuel pipe
union (1) .
aUnclip the fuel pipe. 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 goggles with side protectors for this opera-
tion.
IMPORTANT
Wear latex gloves during the operation.
IMPORTANT
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see 13B, Diesel injection, Diesel
injection: Precautions for the repair, page
13B-1) .
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
120049
WARNING
To prevent impur ities from entering the circuit,
plugs must be fitted to the openings of all the fuel
circuit components exposed to the open air.
WARNING
Keep the pipe unions away from contaminated
areas.

13A-7
FUEL SUPPLY
Electric diesel fuel heater: Removal - Refitting
C44, and K9K
13A
REMOVAL
I - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the vehicle on a two-post lift ( (see Vehicle:
Towing and lifting) ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the electric diesel fuel heater electrical
connector (1) .
aRemove the nut (2) from the electric diesel fuel heat-
er mounting on the body.
aDisconnect the inlet and outlet fuel supply pipes (3)
from the electric diesel fuel heater.
aRemove the electric diesel fuel heater and its mount-
ing from the vehicle.
aSeparate the electric diesel fuel heater from its
mounting, letting it flow.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aFit then lock the electric diesel fuel heater to its
mounting.
aFit the electric diesel fuel heater and its mounting to
the vehicle.
aConnect the electric diesel fuel heater inlet and out-
let fuel supply pipes.
aRefit the electric diesel fuel heater mounting nut on
the body.
aTighten the diesel heater mounting nut on the body.
aConnect the electric diesel fuel heater electrical con-
nector.
aPrime the diesel circuit using the manual priming
pump (4) .
aStart the engine then let it run for a few minutes to
check that it starts properly and to check that there
are no leaks.
II - FINAL OPERATION.
aDeal with possible fuel leaks.
120049
Note:
Make preparations for fuel outfl ow.
120045

13B-14
DIESEL INJECTION
Camshaft position sensor: Removal - Refitting
C44, and K9K
13B
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aParts always to be replaced:
-axle subframe bolt.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift ( (see Vehicle:
Towing and lifting) ).
aRemove the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aLift the engine with the support of the (Mot. 1672) so
as to be able to easily access the camshaft position
sensor bolt.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the connector (1) from the camshaft po-
sition sensor.
aRemove:
-the bolt (2) from the camshaft position sensor,
-the camshaft position sensor.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the camshaft position sensor,
-the camshaft position sensor bolt.
aTorque tighten the camshaft position sensor bolt
(8 Nm).
aConnect the camshaft position sensor connector.
II - FINAL OPERATION.
aLower the engine with the support of the (Mot. 1672)
to position the engine, approximately in its normal
position.
aRefit the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) , Special tooling required
Mot. 1672Low er engine support.
Tightening torquesm
camshaft position sen-
sor bolt8 Nm
120326