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

Contents
Engine cooling fan assembly:
Removal - Refitting 19A-51
Coolant pump inlet pipe:
Removal - Refitting 19A-58
Expansion bottle: Removal -
Refitting 19A-64
Coolant temperature sensor:
Removal - Refitting 19A-66
19B EXHAUST
Exhaust: List and location of
components 19B-1
Exhaust: Precautions for the
repair 19B-8
Catalytic converter: Removal
- Refitting 19B-12
Expansion chamber :
Removal - Refitting 19B-23
Intermediate pipe: Removal -
Refitting 19B-28
Silencer : Removal - Refitting 19B-31
19C TANK
Fuel tank: Draining 19C-1
Fuel tank: Removal -
Refitting 19C-4
Filler neck: Removal -
Refitting 19C-11
Fuel level sensor module:
Removal - Refitting 19C-13 19A COOLING
19D ENGINE MOUNTING
Suspended engine
mounting: Tightening torque 19D-1
Left-hand suspended engine
mounting: Removal -
Refitting 19D-4
Right-hand suspended
engine mounting: Removal -
Refitting 19D-13
Lower engine tie-bar:
Removal - Refitting 19D-18

10A-6
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
K9K
10A
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). Special tooling required
Tav. 476Ball joint extractor.
Tav. 1233-01Tooling for carrying out opera-
tions on the axle subframe.
Equipment required
flywheel immobiliser
safety strap(s)
Tightening torquesm
lowe r cylinder block
bolts14 Nm
multifunction support
bolt on the sump25 N.m
sump bolts on the gear-
box casing44 Nm
subframe front bolts62 N.m
subframe rear bolts105 Nm
subframe rear tie rod
inner bolts21 N.m
subframe rear tie rod
outer bolts90 N.m
lower ball joint bolts62 N.m
track rod end nuts37 N.m
subframe tie-rod upper
bolts21 N.m
subframe tie-rod lower
bolts62 N.m
bolts of the front right-
hand driveshaft relay
bearing44 N.m
bolt of the front right-
hand driveshaft relay
bearing bracket21 N.m
relay bearing bolts on
the front right-hand
driveshaft44 N.m
right-hand driveshaft
relay bearing closure
panel bolts21 Nm
catalytic converter
upstream stay bolt on
the cylinder block44 N.m
catalytic converter
downstream stay bolt on
the sump44 Nm
catalytic converter
downstream stay bolts
on the catalytic con-
verter26 Nm
universal joint bolt24 N.m Tightening torquesm

10A-11
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
K9K
10A
aApply:
-four beads (17) of SILICONE ADHESIVE SEAL-
ANT (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) with a
diameter of 5 mm,
-two drops (18) of SILICONE ADHESIVE SEAL-
ANT (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) with a
diameter of 5 mm at the intersection between the
cylinder block and the crankshaft nose closure
panel.II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the oil sump fitted with a new seal.
aTighten to torque and in order the lower cylinder
block bolts (14 Nm).
aTighten the following until contact is made, and then
to torque:
-the multifunction support bolt on the sump (25
N.m).
-the sump bolts on the gearbox casing (44 Nm).
III - FINAL OPERATION
aRefit the subframe, gradually tightening the nuts of
the (Tav. 1233-01).
aRemove the threaded rods of the tool (Tav. 1233-
01) one by one, replacing them with new subframe
mounting bolts.
aTighten to torque:
-the subframe front bolts (62 N.m),
20167
20166
Note:
Ensure that the oil pump strainer fits well into the
correct location in the oil splash plate.
Note:
Take care not to damage the sump seal when fit-
ting the sump on the cylinder block.
20171

10A-12
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
K9K
10A
-the subframe rear bolts (105 Nm),
-the subframe rear tie rod inner bolts (21 N.m),
-the subframe rear tie rod outer bolts (90 N.m).
aRefit the radiator mounting cross member (see Ra-
diator mounting cross member: Removal - Refit-
ting) (41A, Front lower structure).
aDetach the radiator and the intercooler from the up-
per cross member using a safety strap(s).
aDetach the radiator from the upper cross member
using a safety strap(s).
aRefit:
-the rear engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the lower ball joints,
-the track rod ends.
aTighten to torque:
-the lower ball joint bolts (62 N.m),
-the track rod end nuts (37 N.m).
aRefit the subframe tie rod upper bolts.
aTighten to torque:
-the subframe tie-rod upper bolts (21 N.m),
-the subframe tie-rod lower bolts (62 N.m).
aRefit the front right-hand driveshaft relay bearing
aTighten to torque:
-the bolts of the front right-hand driveshaft relay
bearing (44 N.m),
-the bolt of the front right-hand driveshaft relay
bearing bracket (21 N.m).aFit the relay bearing on its bearing on the front right-
hand driveshaft.
aTorque tighten the relay bearing bolts on the front
right-hand driveshaft (44 N.m).
aRefit the closure panel of the front right-hand drive-
shaft relay bearing
aTorque tighten the right-hand driveshaft relay
bearing closure panel bolts (21 Nm).
aRefit the catalytic converter upstream stay, by slid-
ing it in relation to the bolt remaining on the sump.
aTighten the following until contact is made and to tor-
que:
-the catalytic converter upstream stay bolt on
the cylinder block (44 N.m),
-the catalytic converter downstream stay bolt on
the sump (44 Nm),
-the catalytic converter downstream stay bolts
on the catalytic converter (26 Nm).
aFit the steering box universal joint equipped with a
new bolt.
aTorque tighten the universal joint bolt (24 N.m).
aRemove the flywheel immobiliser.
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).
aFill up the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) . K9K, and 718
K9K, and 740
K9K, and 718
K9K, and 740
Note:
Ensure that the right-hand dr iveshaft relay bear-
ing closure panel is refi tted the right way round.

10A-13
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
D4F or D7F
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDrain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) .
aRemove the engine undertray.
aRemove the engine flywheel guard
aRemove:
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres), Special tooling required
Tav. 476Ball joint extractor.
Tav. 1233-01Tooling for carrying out opera-
tions on the axle subframe.
Mot. 1716Removes housing with sili-
cone seals.
Equipment required
flywheel immobiliser
Tightening torquesm
sump bolts10 N.m
front subframe bolts62 N.m
rear subframe bolts105 N.m
front end cross member
bolts21 N.m
subframe rear tie rod
inner bolts21 N.m
subframe rear tie rod
outer bolts90 N.m
lower ball joint bolts62 N.m
track rod end nuts37 N.m
subframe tie rod upper
bolts21 N.m
subframe tie rod lower
bolts62 N.m
universal joint24 N.m
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
Note:
The sump is sealed in the factory using silicone
adhesive sealant.
When removing the sump in a workshop, it is
essential to use the After-Sales seal available from
the Parts Department.
D4F, and 772 – D7F
120407
D4F, and 780 or 782

10A-16
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
D4F or D7F
10A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the sump fitted with a new seal,
-the sump bolts.
aTighten to torque and in order the sump bolts (10
N.m).
III - FINAL OPERATION
aRefit the engine flywheel guard.aRefit the subframe, gradually tightening the nuts of
the (Tav. 1233-01).
aRemove the threaded rods of the (Tav. 1233-01)
one by one, replacing them with the subframe
mounting bolts.
aTorque tighten:
-the front subframe bolts (62 N.m),
-the rear subframe bolts (105 N.m),
-the front end cross member bolts (21 N.m)
-the subframe rear tie rod inner bolts (21 N.m),
-the subframe rear tie rod outer bolts (90 N.m).
aRefit:
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the lower arm ball joints,
-the lower ball joint bolts,
-track rod ends,
-the track rod end nuts,
aTorque tighten:
-the lower ball joint bolts (62 N.m),
-the track rod end nuts (37 N.m).
aRefit the subframe tie rod upper bolts.
aTorque tighten the subframe tie rod upper bolts
(21 N.m).
aTorque tighten the subframe tie rod lower bolts
(62 N.m).
aFit the steering box universal joint.
aRefit the universal joint bolt.
aTorque tighten the universal joint (24 N.m).
aRemove the flywheel immobiliser.
aRefit:
-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).
18643
D4F, and 772 – D7F
D4F, and 780 or 782

10A-18
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: 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 dipstick,
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the engine undertray.
aDrain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) .
aRemove:
-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),-the rear 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).
aRemove:
-the front right-hand driveshaft flange bolt (1) on the
relay bearing,
-the bolts (2) from the front right-hand driveshaft re-
lay bearing,
-the front right-hand driveshaft relay bearing. Tightening torquesm
sump bolts (initial
torque)14 N.m
sump bolts14 N.m
sump bolts on the gear-
box44 N.m
bolt mounting the multi-
function support on the
sump25 N.m
catalytic pre-converter
upstream bracket bolt44 N.m
driveshaft relay bearing
bolts44 N.m.
right-hand driveshaft
bracket bolt on the relay
bearing21 N.m
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
128800

10A-21
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
K4M
10A
aPretighten in order (1) , (2) , (19) , (20) , (17) , (18)
the sump bolts (initial torque) (14 N.m).
aTighten to torque and in order the sump bolts (14
N.m).
aTorque tighten:
-the sump bolts on the gearbox (44 N.m),
-the bolt mounting the multifunction support on
the sump (25 N.m).
III - FINAL OPERATION
aTorque tighten the catalytic pre-converter up-
stream bracket bolt (44 N.m).
aRefit the driveshaft relay bearing.
aTorque tighten:
-the driveshaft relay bearing bolts (44 N.m.),
-the right-hand driveshaft bracket bolt on the re-
lay bearing (21 N.m).
aRefit:
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the rear 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 dipstick,
-the engine undertray.
aTop up the engine oil (see 10A, Engine and cylin-
der block assembly, Engine oil: Draining - Refill-
ing, page 10A-22) .
20171

10A-22
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine oil: Draining - Refilling
D4F or D7F
10A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aParts always to be replaced :
-copper seal.aConsumable (see Vehicle: Parts and consuma-
bles for the repair) (04B, Consumables - Products).
-Engine oil (see Engine oil: Specifications) (Tech-
nical Note 6013A, 04A, Lubricants).
I - OIL SERVICE
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment). Special tooling required
Mot. 10188 mm square engine drain
plug spanner.
Equipment required
oil change wrench
oil recovery tray
torque wrench
oil change end piece with an 8 mm square drive
Tightening torquesm
drain plug20 N.m
EngineAverage oil capacity
(adjusting using dipstick) (l)
Oil change with-
out filter
replacementOil change with
filter replace-
ment
D7F
3.8 4
D4F
WARNING
Always check the oil level using the dipstick.
Do not exceed the maximum level on the dipstick
(could destroy the engine).
Correct the engine oil level if necessary before
deliver ing the vehicle to the customer.
Note:
When topping up the engine oil, always leave at
least 10 minutes before checking the level with a
dipstick.

10A-24
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine oil: Draining - Refilling
D4F or D7F
10A
Copper seal
aRefit the new seal on the plug, positioning the
groove towards the plug.
aTorque tighten the drain plug (20 N.m) using
torque wrench and a oil change end piece with
an 8 mm square drive.
II - FILLING
aFill the engine with oil, observing the recommended
amount.
aWait at least 10 minutes.
aCheck the oil level using the dipstick.
aTop up the engine oil level if necessary.
aRefit:
-the engine oil filler cap,
-the dipstick.
113764