K4M RENAULT TWINGO RS 2009 2.G Engine And Peripherals Owner's Guide

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.

10A-110
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: 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 engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-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 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 engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).aRemove:
-the lower 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),
-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 seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the « engine - gearbox » assembly (see 10A, En-
gine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) (21A, Manual gearbox),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) ,
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch).
II - REMOVAL OPERATION
aRemove:
-the flywheel bolts,
-the (Mot. 1677) (1) , Special tooling required
Mot. 1677Flywheel locking tool.
Equipment required
refrigerant charging station
Tightening torquesm
flywheel bolts70 N.m
109158

10A-111
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
K4M
10A
-the flywheel.
REFITTING
I - REFITTING PREPARATION OPERATION
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the flywheel bearing face if reusing,
-the crankshaft bearing face.
aAlways replace the flywheel bolts.
II - REFITTING OPERATION
aFit the flywheel.
aFit the new flywheel bolts without tightening them.
aPosition the (Mot. 1677).
aTighten to torque and in order the flywheel bolts
(70 N.m).
III - FINAL OPERATION
aRefit:
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) (21A, Manual gearbox).-the « engine and gearbox » assembly (see 10A,
Engine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) ,
-the differential output seals (see Differential out-
put 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 front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the lower 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 battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aPerform the following operations:
-fill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) ,
-fill the gearbox (see Manual gearbox oils: Drain-
ing - Filling) (21A, Manual gearbox).
-fill the refrigerant circuit using a refrigerant charg-
ing station (see Refrigerant circuit: Draining -
Filling) (62A, Air conditioning).
aRefit the engine undertray.
109158

11A-1
TOP AND FRONT OF ENGINE
Pressure at end of compression: Check
K4M
11A
CHECK
I - PREPARATION OPERATION FOR CHECK
aRemove:
-the coils (see 17A, Ignition, Coils: Removal - Re-
fitting, page 17A-1) ,
-the spark plugs (see 17A, Ignition, Plugs: Re-
moval - Refitting, page 17A-12) .
aDisconnect the injector wiring connector (1) .aConnect a petrol compression gauge (2) .
aPut the vehicle under the starting conditions by posi-
tioning the gear lever in neutral.
II - TEST OPERATION
aActivate the starter until the needle of the petrol
compression gauge stabilises.
aMeasure the cylinder compressions, cylinder by cyl-
inder.
aFully depress the accelerator pedal in order to open
the throttle valve during the compression measure-
ments.
III - FINAL OPERATION
aDisconnect the petrol compression gauge.
aConnect the injector wiring connector.
aRefit:
-the spark plugs (see 17A, Ignition, Plugs: Re-
moval - Refitting, page 17A-12) ,
-the coils (see 17A, Ignition, Coils: Removal - Re-
fitting, page 17A-1) . Equipment required
petrol compression gauge
132371
132338
Note:
It is necessar y to wait for at least 10 seconds
before starting the engine each time (the starter
will not run due to its ther mal protection).

11A-17
TOP AND FRONT OF ENGINE
Accessories belt: 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,
-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).aUnclip:
-the wiring at (1) ,
-the windscreen washer bottle filler neck at (2) ,
-the air conditioning pipe from the right-hand head-
light carrier panel.
aRemove:
-the nut (3) from the right-hand headlight carrier
panel,
-the bolts (4) from the right-hand headlight carrier
panel,
-the right-hand headlight carrier panel. Tightening torquesm
tensioning roller40 N.m
WARNING
Do not r un the engine without the accessories belt
to avoid damaging the crankshaft accessories pul-
ley.
IMPORTANT
Wear cut-resistant gloves during the operation.132339

11A-18
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
K4M
11A
II - REMOVAL OPERATION
aTurn the accessories belt tensioning roller clockwise
using a 16 mm spanner (5) .
aRemove the accessories belt.
aRemove:
-the tensioning roller bolt (6) ,
-the tensioning roller.REFITTING
I - REFITTING PREPARATION OPERATION
aUse a brush to remove any deposits from the crank-
shaft pulley V-grooves.
aparts always to be replaced: Accessories belt.
aparts always to be replaced: Accessories belt
tensioning roller.
II - REFITTING OPERATION
aRefit a new tensioning roller.
aTorque tighten the tensioning roller (40 N.m).
aTurn the accessories belt tensioning roller clockwise
using a 16 mm spanner.
aRefit a new accessories belt.
aGently release the tensioning roller.
aRotate the crankshaft clockwise twice to balance the
accessories belt tension on all pulleys.
III - FINAL OPERATION
aRefit the right-hand headlight carrier panel.
aClip:
-the air conditioning pipe on the right-hand headlight
carrier panel,
-the screen washer bottle filler neck,
-the wiring.
aRefit:
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper
front structure),
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
-the headlights (see Halogen headlight: Removal
- Refitting) (80B, Headlights),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-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),
-the engine undertray.
132377
132376

11A-19
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting
K4M
11A
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).

11A-25
TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: 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 front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the engine undertray,
-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) .II - REMOVAL OPERATION
aRemove:
-the bolt (1) from the crankshaft accessories pulley
by locking the flywheel using a screwdriver,
-the crankshaft accessories pulley.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Crankshaft acces-
sories pulley bolts. Tightening torquesm
crankshaft accessories
pulley bolts120 N.m + 95˚
±± ± ±
10˚
IMPORTANT
Wear cut-resistant gloves during the operation.
WARNING
Do not r un the engine without the accessories belt
to avoid damaging the crankshaft accessories pul-
ley.
133106
14487

11A-26
TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting
K4M
11A
aUse a brush to remove any deposits from the crank-
shaft accessories pulley V grooves.
II - REFITTING OPERATION
aRefit the crankshaft accessories pulley.
aTighten to torque and angle the crankshaft acces-
sories pulley bolts (120 N.m + 95˚ ±± ± ±
10˚) by locking
the engine flywheel using a flat-blade screwdriver.
III - FINAL OPERATION
aRefit:
-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 bonnet catch (see Bonnet lock: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
-the headlights (see Halogen headlight: Removal
- Refitting) (80B, Headlights),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the engine undertray,
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).

11A-53
TOP AND FRONT OF ENGINE
Timing belt: 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,
-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 throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-20) ,
-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), Special tooling required
Mot. 1489TDC locating pin.
Mot. 1368Tool for tightening eccentric
tensioning roller bolt. 8 mm
Torx wrench and 12.7 mm
square.
Mot. 1496Camshaft timing tool.
Mot. 1750Additional tool to suppor t the
camshaft adjusting tool, Mot.
1496.
Mot. 1490-01For locking and adjusting the
camshaft pulle ys.
Mot. 1487Tool for refitting camshaft cov-
ers (57 mm diameter).
Mot. 1488Tool for refitting camshaft cov-
ers (43 mm diameter).
Equipment required
indelible pencil
Tightening torquesm
fixed roller bolt50 N.m
lower timing cover bolts12 N.m
exhaust camshaft pul-
ley nut30 N.m + 84˚
camshaft dephaser pul-
ley bolt100 N.m
timing tension wheel nut27 N.m
TDC setting pin plug20 N.m
upper timing cover bolts41 N.m
upper timing cover nuts41 N.m
rear suspended engine
reinforcement bolt105 N.m
rear suspended engine
mounting bolt on the
rear suspended engine
mounting suppor t105 N.m
rear suspended engine
mounting bolt on the
subframe105 N.m Tightening torquesm