clock RENAULT TWINGO 2009 2.G Engine And Peripherals Workshop Manual

10A-15
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
D4F or D7F
10A
aAttach the cooling radiator to the upper cross mem-
ber.
aRemove:
-the bolts (6) from the front end cross member,
-the subframe bolts (7) .
aRemove the threaded rods of the (Tav. 1233-01)
one by one, replacing them with the subframe
mounting bolts.
aLower the subframe by several centimetres, gradu-
ally loosening the nuts of the (Tav. 1233-01).II - OPERATION FOR REMOVAL OF PART
CONCERNED
1 - Removing the sump with silicone adhesive
sealant
aRemove the sump bolts.
aGradually remove the sump using the (Mot. 1716).
aRemove the sump by pivoting it anti-clockwise to
prevent catching the oil pump strainer.
2 - Removing the sump with an After-Sales seal
aRemove:
-the sump bolts,
-the sump by pivoting it anti-clockwise to prevent
catching the oil pump strainer,
-the sump seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: engine oil sump
seal.
aUse SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to clean
the joint faces:
-of the cylinder block,
-of the sump.
aLeave for approximately ten minutes.
aRemove the residue using a wooden spatula.
aFinish cleaning the parts using a GREY ABRASIVE
PAD (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products).
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease the joint fa-
ces:
-of the cylinder block,
-of the sump.
119336
Note:
This operation requires two people.
Note:
Make sure the threaded rod of the (Tav. 1233-01)
is sufficiently screwed into the threaded hole and
that the nut of the tool is properly resting on the
subframe.
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).

10A-40
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
aRemove:
-the con rod bolts,
-the con rod cap,
-the lower con rod bearing shell.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - products) to clean the bearing mating face on
the con rod cap.aFit the tie rod of the tool (Mot. 1914) on the con rod
body.
aPush the con rod upwards to release the con rod
from the crankpin.
aTurn the crankshaft 90˚ clockwise (timing end).
139300
Note:
If reusing the con rod bearing shells, mark the
position of the lower con rod bearing shell in rela-
tion to the con rod cap.
139310

10A-42
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
a
Fit the lower con rod bearing shell on the con rod
cap using the tool (Mot. 1920).
aPosition the lower con rod bearing shell so that the
ends do not protrude beyond the con rod cap.
aLubricate the surface of the con rod bearing shell
(crankshaft end) using new engine oil.aRemove the tool head with the marking " K9K INF "
and fit the head with the marking " K9K SUP ".
aPosition the upper con rod bearing shell on the tool
(Mot. 1920).
aFit the upper con rod bearing shell on the con rod
body using the tool (Mot. 1920).
aPosition the upper con rod bearing shell so that the
ends do not protrude beyond the con rod body.
aLubricate the surface of the con rod bearing shell
(crankshaft end) using new engine oil.
aPush the con rod - piston assembly back up into
place.
aTurn the crankshaft 90˚ anticlockwise.
aLubricate the crankpin with new engine oil.
aPull the con rod - piston assembly to position the con
rod on the crankshaft.
a
Refit:
-the con rod cap according to the mark made during
removal,
-the new con rod bolts.
aTorque and angle tighten the con rod cap bolts (20
N.m + 45˚ ±± ± ±
6˚).
133814
133815
Note:
The contact surface between the bearing shell
and the con rod must be dry and free of grease.
139318
Note:
Before refitting the con rod cap, ensure that there
are no impurities (filings, cloth lint, etc.) on the
con rod body or cap surfaces.

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-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-11
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
K9K, and STANDARD HEATING
11A
aRemove:
-the multifunction support bolts from the cylinder
block,
-the multifunction support bolt from the sump,
-the equipped multifunction support.
aPlace the multifunction support in a vice.
aRemove:
-the tensioning roller bolt,
-the tensioning roller,
-the air conditioning compressor substitute pulley
bolts,
-the air conditioning compressor substitute pulley.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
1 - Refit the tensioning roller
aPlace the multifunction support in a vice.
aRefit:
-the new air conditioning compressor substitute pul-
ley.
-the air conditioning compressor substitute pulley
bolts,
-the new tensioning roller,
-the tensioning roller bolt,
aTorque tighten:
-the air conditioning compressor substitute pul-
ley bolts (25 Nm),
-the tensioning roller bolt (40 Nm),
aRefit:
-the equipped multifunction support,
-the multifunction support bolt onto the sump,
-the multifunction support bolts onto the cylinder
block.aTighten to torque and in order:
-the bolts mounting the multifunction support
on the cylinder block (44 Nm),
-the bolt mounting the multifunction support on
the sump (25 Nm).
aRefit:
-the alternator with its lower bolt fitted,
-the alternator upper bolt.
aTorque tighten the alternator bolts (25 Nm).
aPosition the alternator wiring harness.
aRefit the nut to the alternator wiring harness.
aAttach the connector to the alternator.
2 - Refit the accessories belt
aPartially refit the new accessories belt:
-positioning it between the air conditioning com-
pressor substitute pulley and the multifunction sup-
port,
-passing it over its slot between the RH side mem-
ber and the crankshaft accessories, tensioning roll-
er and alternator pulleys.
aTurn the accessories belt auto tensioner clockwise
using a 16 mm spanner
aFit the belt on the air conditioning compressor sub-
stitute pulley.
aGently release the tensioning roller.
120315

11A-15
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
D4F, and 780 or 782, and STANDARD HEATING
11A
aTension the accessories belt by turning the tension-
ing roller anti-clockwise with a 20 mm open-jawed
spanner.
aAdjust the accessories belt tension using the (Mot.
1715) or (Mot. 1505) (see ) (Technical Note 3786A,
10A, Engine and peripherals).
aWithout locking, tighten the bolt (5) on the tensioning
roller with a 16 mm open-jawed spanner, while
keeping the tensioning roller tension at the adjust-
ment value using a 20 mm open-jawed spanner.aThe accessories belt tension value is 210 Hz ±± ± ±
10.
aTorque tighten the tensioning roller bolt (44 N.m)
using a 16 mm socket and a repositioner, while
keeping the tensioning roller tension at the adjust-
ment value with a 20 mm 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 sub-frame tie-rod.
aRefit the upper bolt on the sub-frame tie-rod.
aTorque tighten:
-the sub-frame tie-rod lower bolt (62 N.m),
-the sub-frame tie-rod upper bolt (21 N.m).
aRefit:
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
11038213511
(1) Crankshaft
(2) Alternator
(3) Tensioning roller
(4) Measur ing point

11A-18
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
K4M
11A
II - REMOVAL OPERATION
aTurn the accessories belt tensioning roller clockwise
using a 16 mm spanner (5) .
aRemove the accessories belt.
aRemove:
-the tensioning roller bolt (6) ,
-the tensioning roller.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.
II - REFITTING OPERATION
aRefit a new tensioning roller.
aTorque tighten the tensioning roller (40 N.m).
aTurn the accessories belt tensioning roller clockwise
using a 16 mm spanner.
aRefit a new accessories belt.
aGently release the tensioning roller.
aRotate the crankshaft clockwise twice to balance the
accessories belt tension on all pulleys.
III - FINAL OPERATION
aRefit the right-hand headlight carrier panel.
aClip:
-the air conditioning pipe on the right-hand headlight
carrier panel,
-the screen washer bottle filler neck,
-the wiring.
aRefit:
-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.
132377
132376

11A-28
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
D7F, and 800
11A
aRemove the cap (3) from the upper timing cover.
aTurn the engine clockwise (timing end) until the
mark on the camshaft sprocket is aligned with the
mark on the upper timing cover.
aInsert the TDC setting pin (Mot. 1054) (4)
aRemove the ignition interference suppressor.
aDisconnect the fuel supply pipe.
aRemove the following covers:
-upper timing,
-middle timing,-lower timing.
II - REMOVAL OF PART CONCERNED
aMake a marking on the rocker cover (5) in line with
the camshaft sprocket mark
aUndo the tensioning roller nut (6) .
aRemove the timing belt.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aLine up the marks on the timing belt with those on
the camshaft sprocket and crankshaft sprocket.
aRefit:
-the new timing belt,
-the new tensioning roller.
aTighten the tensioning roller.
aRemove the TDC setting rod (Mot. 1054).
107259
99795
1041