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

11A-114
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K9K
11A
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 ) (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 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),
-the halogen headlights (see Halogen headlight:
Removal - Refitting) (80B, Headlights),
-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 timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) .
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aRemove:
-the nut from the dipstick guide,
-the dipstick guide.
aDisconnect:
-the injector connectors,
-the heater plug connectors ,
-the connectors to the high pressure pump,
-injector rail pressure sensor connector,
-the accelerometer connector.
aRemove the nut from the engine wiring channel.
aMove aside the engine wiring.
aDisconnect the fuel inlet and return pipes from the
high pressure pump. Special tooling required
Mot. 1202-01Clip pliers for hose clips
(large size).
Mot. 1202-02Clip pliers for hose clips
(small size)
Mot. 1448Remote operation pliers for
hose clips .
Equipment required
cylinder head bolt tightening gauge (angular mea-
suring type)
Tightening torquesm
cylinder head bolts (ini-
tial torque)25 N.m
cylinder head bolts270˚ ±± ± ±
10˚
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
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-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-116
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K9K
11A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the cylinder head bolts,
-the cylinder head,
-the cylinder head gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Cylinder head gas-
ket.
aparts always to be replaced: cylinder head bolts.
aparts always to be replaced: turbocharger oil
pipe seal.1 - Cleaning the cylinder head
aApply SUPER CLEANER FOR JOINT FACES (see
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products) to the areas to be
cleaned.
aWait for approximately ten minutes.
aRemove the residue using a wooden spatula.
aFinish cleaning with a grey abrasive pad.
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) .
19712
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
Do not allow this product to dr ip onto the paint-
work.
Clean the cylinder head carefully to prevent for-
eign bodies from entering the oil supply and
return galleries.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.
WARNING
Protect the oilway so that foreign bodies do not
enter the oil pipes in the cylinder head.
Failure to follow this instruction could lead to the
blocking of the oilways, resulting in a rapid deteri-
oration of the camshaft.
Note:
The cylinder head bolts must not be lubricated
before being fitted.
WARNING
No regr inding of the cylinder head is permitted.

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-118
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K9K
11A
-the connectors to the high pressure pump,
-the heater plug connectors ,
-the injector connectors.
aRefit:
-the engine wiring channel nut,
-the dipstick guide,
-the dipstick guide nut.
aRefit:
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) .
-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 halogen headlights (see Halogen headlight:
Removal - Refitting) (80B, Headlights),
-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 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).
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) .
aRefit the engine cover.

11A-119
TOP AND FRONT OF ENGINE
Cylinder head: 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.
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
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 coils (see 17A, Ignition, Coils: Removal - Re-
fitting, page 17A-1) ,-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-20) ,
-the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-the oil decanter (see 11A, Top and front of en-
gine, Oil decanter: Removal - Refitting, page
11A-147) ,
-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 lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-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) ,
-the camshaft seals on the timing end (see 11A,
Top and front of engine, Camshaft seal, timing
end: Removal - Refitting, page 11A-138) ,
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) , Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Mot. 1202-01Clip pliers for hose clips
(large size).
Mot. 1202-02Clip pliers for hose clips
(small size)
Tightening torquesm
cylinder head bolts (ini-
tial torque)20 N.m
cylinder head bolts240˚ ±± ± ±
6˚
IMPORTANT
Wear cut-resistant gloves during the operation.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.

11A-120
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K4M
11A
-the camshafts (see 11A, Top and front of engine,
Camshaft: Removal - Refitting, page 11A-82) .
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 exhaust manifold (see 12A, Fuel mixture, Ex-
haust manifold: Removal - Refitting, page 12A-
48) .
aRemove:
-the dipstick,
-the bolts (1) from the dipstick guide,
-the dipstick guide.aUsing the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) remove:
-the cooling radiator top hose clip (2) on the water
chamber.
-the heater matrix inlet hose clip (3) on the water
chamber.
aDisconnect:
-the cooling radiator top hose from the water cham-
ber.
-the heater matrix inlet hose of the water chamber,
-the connector (4) from the coolant temperature
sensor.
aUnclip the water chamber wiring.
132368
128616

11A-121
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K4M
11A
aRemove:
-the bolts (5) of the engine wiring channel,
-the wiring bracket bolt (6) .
aMove the wiring bracket away from the water cham-
ber.
aDisconnect the injector connectors (7) .
aMove the injector wiring to one side.II - REMOVAL OPERATION
aRemove:
-the cylinder head bolts,
-the cylinder head,
-the cylinder head gasket.
REMOVAL
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: cylinder head bolts.
parts always to be replaced: Cylinder head gas-
ket.
127347
132390
103259

11A-122
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K4M
11A
CLEANING THE CYLINDER HEAD
a
aUse SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to clean:
-the cylinder head gasket face if being reused,
-the cylinder block gasket face.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to degrease:
-the cylinder head gasket face if being reused,
-the cylinder block gasket face.
aCheck for gasket face deformation using a ruler and
a set of shims.
The maximum deformation is 0.05 mm.aStrip the cylinder head (see Cylinder head: Strip-
ping - Rebuilding) (Technical Note 6023A, 10A,
Engine and peripherals).
aTest the cylinder head for possible cracks using the
cylinder head test kit (see Garage Equipment Cat-
alogue).
aRebuild the cylinder head (see Cylinder head:
Stripping - Rebuilding) (Technical Note 6023A,
10A, Engine and peripherals).
aPosition the pistons at mid-stroke.
aCheck that the centring dowel (6) is on the cylinder
block.
aRefit a new cylinder head gasket. IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
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
The joint faces must be clean, dr y and free from
grease (avoid finger marks).
WARNING
Do not allow this product to drip onto the paint-
work.
Clean the cylinder head carefully to prevent for-
eign bodies from entering the oil supply and
return galleries.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.
WARNING
No regrinding of the cylinder head is permitted.
128611

11A-123
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K4M
11A
II - REFITTING OPERATION
aRefit:
-the cylinder head,
-the new cylinder head bolts.
aWithout tightening, fit the cylinder head bolts in or-
der.
aPretighten to torque and in order the cylinder head
bolts (initial torque) (20 N.m).
aCheck that all of the new cylinder head bolts are
tightened to the correct torque (20 N.m).
aAngle tighten in order the cylinder head bolts (240˚
±± ± ±
6˚).III - FINAL OPERATION
aPosition the injector wiring.
aConnect the injector connectors.
aFit the wiring bracket on the water chamber.
aRefit:
-the wiring bracket bolt on the water chamber,
-the bolts of the engine wiring channel.
aClip on the water chamber wiring.
aConnect:
-the coolant temperature sensor connector,
-the heater matrix inlet hose to the water chamber,
-the cooling radiator top hose to the water chamber.
aUsing the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) fit:
-the cooling radiator top hose clip on the water
chamber,
-the heater matrix inlet hose clip on the water cham-
ber.
aRefit:
-dipstick guide ,
-the dipstick,
-the exhaust manifold (see 12A, Fuel mixture, Ex-
haust manifold: Removal - Refitting, page 12A-
48) .
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the camshafts (see 11A, Top and front of engine,
Camshaft: Removal - Refitting, page 11A-82) ,
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) ,
-the camshaft seals on the timing end (see 11A,
Top and front of engine, Camshaft seal, timing
end: Removal - Refitting, page 11A-138) ,
-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 crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,
103259
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.
WARNING
Do not oil the new bolts. Be sure to oil bolts
being reused.
WARNING
Do not retighten the cylinder head bolts after
applying this procedure.