wiring RENAULT TWINGO RS 2009 2.G Engine And Peripherals Owner's Manual

11A-70
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 772
11A
II - REFITTING OPERATION FOR PART
CONCERNED
aApply a bead (1) of SILICONE ADHESIVE SEAL-
ANT (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to the
camshaft bearings 1 and 5, as well as around the
rocker cover rear bolts.
aFit the rocker cover with a new gasket.aTighten the rocker cover bolts in order.
III - FINAL OPERATION
aRefit:
-the ignition coil (see 17A, Ignition, Coils: Remov-
al - Refitting, page 17A-1) ,
-the inlet distributor (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) .
aClip on the rocker cover electric wiring harnesses.
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
18441
20005
110422

11A-72
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 780 or 782 or 784
11A
a
aRemove the turbocharger outlet air pipe bolt (3) on
the throttle valve.
aMove the turbocharger outlet air pipe on the turbo-
charger to one side, following the direction shown by
the arrow (4) .aDisconnect the turbocharger air outlet pipe from the
turbocharger.
aMove aside the turbocharger air outlet pipe.
aUnclip the wiring harness from the upstream oxygen
sensor (7) .
aRemove:
-the bolts (6) from the heat shield,
-the heat shield,
-the filler neck bolt (8) ,
-the filler neck,
-the ignition coil (see 17A, Ignition, Coils: Remov-
al - Refitting, page 17A-1) .
122834
122673
Note:
If the turbocharger air outlet pipe tightening clip
(1) is removed, the flexible rubber pipe (2) and
the tightening clip (1) must be replaced.
Note:
If the clip (5) is removed from the heat resistant
protector, the latter must be replaced.
120957

11A-75
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 780 or 782 or 784
11A
aClip the upstream oxygen sensor wiring harness into
place.
aPosition the turbocharger air outlet pipe.
aPush the turbocharger outlet air pipe clip, following
the direction shown by the arrow (10) .
aConnect the turbocharger air outlet pipe onto the tur-
bocharger.
aRefit:
-the turbocharger outlet air pipe bolt on the throttle
valve,
-the air filter unit support,
-the air filter box mounting bolt,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
122666

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-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-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-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.