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

11A-125
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
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 ) (80A, Battery).
aRemove:
-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).
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),
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-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) .
aRemove:
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the intake distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) .
aRemove:
-the inlet manifold (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-the air filter box retaining belts,
-the air filter unit.
aRemove:
-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) .
aPerform the following operations:
-drain the engine oil (see 10A, Engine and cylin-
der block assembly, Engine oil: Draining - Re-
filling, page 10A-22) ,
-drain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aRemove the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29) . 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 bolts230˚ ±± ± ±
6
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
D4F
D4F
D7F

11A-126
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
11A
aDisconnect the coolant temperature sensor connec-
tor (1) .
aSeparate the water chamber hose clips side using
the tool (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02).
aDisconnect the water chamber hoses.
aRemove the ball joint bracket bolts (2) .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.
114326
120403
18641

11A-127
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
11A
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.
aComplete the cleaning operation using a grey abra-
sive 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) .
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.
aCheck for the cylinder head centring dowels on the
cylinder block.
aRefit:
-a new cylinder head gasket,
-the cylinder head.
Cylinder head tightening procedure
aRefit the new cylinder head bolts.
aFit the cylinder head bolts, without tightening them. 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 drip onto the paint-
work.
Clean the cylinder head carefully to avoid any
foreign bodies entering the oil return and supply
pipes.
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 regrinding of the cylinder head is permitted.
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.

11A-128
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
11A
aTighten to torque and in order the cylinder head
bolts (initial torque) (20 N.m).
aCheck that all the cylinder head bolts are pretight-
ened to 20 Nm.
aAngle tighten in order the cylinder head bolts (230˚
±± ± ±
6).
III - FINAL OPERATION
aRefit the exhaust bracket bolts.
aTighten the exhaust bracket bolts.
aConnect the water chamber hoses.
aFit the water chamber hose clips using the tool (Mot.
1448) or (Mot. 1202-01) or (Mot. 1202-02).
aConnect the coolant temperature sensor connector.
aRefit:
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) ,
-the ignition coil.
aRefit:
-the inlet manifold (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
aRefit:
-the air filter unit,
-the air filter box retaining belts,
-the intake distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) .
aRefit:
-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 accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) .
aRefit:
-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).
aRefit:
-a new oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29) ,
-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).
aPerform the following operations:
-top up the engine oil (see 10A, Engine and cylin-
der block assembly, Engine oil: Draining - Re-
filling, page 10A-22) ,
18641
D4F
D7F
D4F

11A-129
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
11A
-fill and bleed the coolant circuit (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) .
aConnect the battery (see ) (80A, Battery).
aCheck that there are no leaks.

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-131
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
aRemove the bolts (2) on the intercooler outlet air
pipe.
aMove the intercooler outlet air pipe away from the
throttle valve.
aUndo the compressor discharge valve air pipe clip
(3) .
aDisconnect:
-the turbocharging solenoid valve connector to the
turbocharger,
-the compressor discharge valve air pipe from the
air filter unit outlet air pipe.aUnclip the injection wiring from the inlet manifold.
aDisconnect:
-the upstream oxygen sensor connector (4) .
-the air inlet pressure connector (5) ,
-the injector rail - injector wiring connector (6) ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the throttle body connector ,
-the coolant temperature sensor connector.
aDisconnect the petrol supply union on the injector
rail - injector.
aPlug the openings.
aMove aside the engine wiring.
122390121765
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-132
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
aMove aside the clips (7) from the cooling hoses us-
ing the (Mot. 1448).
aDisconnect the cooling hoses.
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.
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.
121723
18641
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.

11A-133
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
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) .
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.
aCheck for the cylinder head centring dowels on the
cylinder block.
aFit a new cylinder head gasket onto the cylinder
block, positioning the marking (8) on the oil filter
side.
aRefit 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) (20 N.m).
aCheck that the cylinder head bolts are tightened to
20 N.m.
aAngle tighten in order the cylinder head bolts (230˚
±± ± ±
6˚).
III - FINAL OPERATION
aConnect the cooling hoses.
aRefit:
-the cooling hose clips using the (Mot. 1448),
-the engine wiring.
aRemove the blanking plugs.
aConnect:
-the petrol inlet union on the injector rail - injectors.
-the coolant temperature sensor connector,
-the throttle body connector ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the injector rail - injector wiring connector,
-the air inlet pressure connector.
-the upstream oxygen sensor connector.
aClip the injection wiring onto the inlet manifold.
aConnect:
-the compressor discharge valve air pipe to the air
filter unit outlet air pipe, WARNING
No regrinding of the cylinder head is permitted.
19598
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.
18641

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).