catalytic converter RENAULT TWINGO RS 2009 2.G Engine And Peripherals User Guide

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-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-104
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aConnect:
-the top hose on the water chamber,
-the hoses on the heater matrix.
aUsing the (Mot. 1448), fit:
-the clip on the top hose on the water chamber,
-the clip on each hose on the heater matrix.
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .
aRefit:
-the differential output seal (see Differential output
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 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 strap of the « engine cooling radiator -
condenser » assembly on the front upper cross
member,
-the engine tie-bar (see 19D, Engine mounting,
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 fuel injection computer (see 17B, Petrol injec-
tion, Petrol injection computer: Removal - Refit-
ting, page 17B-20) .
aRefit the battery (see Battery: Removal - Refitting)
(80A, Battery).
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .aRefill:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-and bleed the cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the engine if necessary (see 10A, Engine and cyl-
inder block assembly, Engine oil: Draining - Re-
filling, page 10A-22) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aBleed the clutch circuit (see Clutch circuit: Bleed)
(37A, Mechanical component controls).
aRefit the engine undertray.

11A-115
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K9K
11A
aFit blanking plugs to the fuel pipes and the high pres-
sure pump (see 13B, Diesel injection, Diesel in-
jection: Precautions for the repair, page 13B-1) .
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aUnclip:
-the breather pipe on the gearbox,
-the wiring on the engine lifting eye on the gearbox
side.
aMove aside the engine wiring.
aDisconnect the brake servo pipe from the vacuum
pump.
aRemove the cooling hose clip from the EGR cooler
using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
aDisconnect the cooling hose from the EGR cooler.
aSeparate the clip on the cooling hose of the coolant
pump inlet pipe using the tool (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
aDisconnect the cooling hose from the coolant pump
inlet pipe.
aRemove the heater matrix cooling hose clip from the
water chamber using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448).
aDisconnect:
-the heater matrix cooling hose from the water
chamber,
-the coolant temperature sensor connector.
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .aRemove:
-the oil return pipe bolts (1) from the turbocharger,
-the oil return pipe by detaching it from the cylinder
block,
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) ,
-the two high pressure pipes between the rail and
injector at the timing end (see 13B, Diesel injec-
tion, High pressure pipe between rail and injec-
tor: Removal - Refitting, page 13B-39) ,
-the timing end bracket bolt from the air filter box,
-the timing end bracket from the air filter box.
112327

11A-117
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K9K
11A
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.
aRefit:
-a new cylinder head gasket,
-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) (25 N.m).
aCheck that the cylinder head bolts are tightened to
25 Nm.
aAngle tighten the cylinder head bolts (270˚ ±± ± ±
10˚) in
order using a cylinder head bolt tightening gauge
(angular measuring type).
III - FINAL OPERATION
aRefit:
-the timing end bracket on the air filter box.
-the timing end bracket bolt on the air filter box,-the two high pressure pipes between the rail and
injector at the timing end (see 13B, Diesel injec-
tion, High pressure pipe between rail and injec-
tor: Removal - Refitting, page 13B-39) ,
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) ,
-the oil return pipe fitted with new seals, fitting it into
the cylinder block (see 12B, Turbocharging, Tur-
bocharger oil pipe: Removal - Refitting, page
12B-12) .
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .
aConnect:
-the coolant temperature sensor connector,
-the heater matrix cooling hose to the water cham-
ber.
aFit the clip on the heater matrix cooling hose onto
the water chamber using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
aConnect the coolant pump inlet pipe cooling hose.
aFit the cooling hose clip at the coolant pump inlet
pipe end using the (Mot. 1202-01) or (Mot. 1202-02)
or (Mot. 1448).
aConnect the EGR cooler cooling hose.
aFit the cooling hose clip at the EGR cooler end using
the (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
aConnect the brake servo pipe onto the vacuum
pump.
aFit the engine wiring.
aClip:
-the breather pipe onto the gearbox,
-the wiring on the engine lifting eye on the gearbox
side.
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
aRemove the blanking plugs from the fuel pipes and
high pressure pump.
aConnect the fuel inlet and return pipes to the high
pressure pump.
aFit the engine wiring.
aConnect:
-the accelerometer connector,
-injector rail pressure sensor connector, 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.
19712

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-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).

12A-49
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
D4F, and 772 – D7F
12A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the nuts (3) from the exhaust manifold,
-the exhaust manifold,
-the exhaust manifold gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
aClean the joint faces.
aparts always to be replaced: exhaust manifold
seal.
aparts always to be replaced: ring between ex-
haust manifold and catalytic converter.
aTorque tighten the exhaust manifold studs on the
cylinder head (10 N.m).
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the exhaust manifold nuts.aTighten to torque and in order the exhaust manifold
nuts (25 N.m).
III - FINAL OPERATION
aRefit:
-the heat shield on the exhaust manifold,
-the heat shield bolts on the exhaust manifold.
aRefit the exhaust flange nuts.
aCheck:
-that there is no exhaust gas leak,
-that there is no contact between the underbody and
the exhaust pipe,
120312
Note:
If any of the studs become loose during these
operations, coat them with HIGH STRENGTH
THREAD LOCK (see Vehicle: Parts and con-
sumables for the repair) (04B, Consumables -
Products).
120312
D4F

12A-50
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K9K
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 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) ,
-the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting, page 12B-4) .aRemove:
-the bolts (1) from the lifting eye at the timing end,
-the lifting eye (2) ,
-air inlet metal tube (3) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the rigid exhaust gas recirculation pipe (see
14A, Antipollution, Exhaust gas recirculation rig-
id pipe: Removal - Refitting, page 14A-19) .
aUndo the EGR unit bolts (4) a few turns. Equipment required
cleaning trough
par ts washer
compressed air nozzle
Tightening torquesm
exhaust manifold studs
on the cylinder head9 N.m
exhaust manifold nuts26 N.m
exhaust gas recircula-
tion unit bolts25 N.m
121635
121636

12A-51
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K9K
12A
aRemove:
-the nuts (5) from the exhaust manifold,
-the exhaust manifold,
-the exhaust manifold gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: exhaust manifold
seal.
aAlways replace:
-the air inlet metal tube seals.
aIf the exhaust manifold is being reused, clean it us-
ing a cleaning trough or a parts washer then dry it
using a compressed air nozzle.
aClean the bearing faces using ABRASIVE PADS
on:
-of the cylinder head - exhaust manifold,
-of the exhaust manifold - EGR rigid pipe,
-of the exhaust manifold - turbocharger,
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) and CLEAN CLOTHS to degrease
the bearing faces:
-of the cylinder head - exhaust manifold,
-of the exhaust manifold - EGR rigid pipe,
-of the exhaust manifold - turbocharger,aIf replacing, torque tighten the exhaust manifold
studs on the cylinder head (9 N.m).
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-a new exhaust manifold seal,
-the exhaust manifold.
aTorque tighten in order the exhaust manifold nuts
(26 N.m).
aFit the exhaust gas recirculation unit bolts.
aTorque tighten the exhaust gas recirculation unit
bolts (25 N.m).
aRefit the rigid exhaust gas recirculation pipe (see
14A, Antipollution, Exhaust gas recirculation rig-
id pipe: Removal - Refitting, page 14A-19) .
III - FINAL OPERATION
aRefit:
-a new seal on the air inlet metal tube,
-the air inlet metal tube,
-the lifting eye on the timing end,
-the bolts from the lifting eye, timing end,
-the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting, page 12B-4) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
113561
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).
113561