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

11A-58
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
K4M
11A
II - REFITTING OPERATION
1 - Adjusting the timing
a
aSet the camshaft grooves horizontally and below the
centre line by turning the camshafts with the (Mot.
1496) if necessary.
aFit the (Mot. 1496) with the (Mot. 1750).aFit:
-the (Mot. 1496) fitted with the (Mot. 1750) on the
end of the camshaft,
-a lifting eye bolt to secure the (Mot. 1496).
aIf fitting a new camshaft dephaser, check the
dephaser locking mechanism (see 11A, Top and
front of engine, Camshaft dephaser: Removal -
Refitting, page 11A-135) .
aRefit the camshaft dephaser (see 11A, Top and
front of engine, Camshaft dephaser: Removal -
Refitting, page 11A-135) . Note:
If the stud loosens with the nut (see 11A, Top
and front of engine, Camshaft: Removal -
Refitting, page 11A-82) (Technical Note 3887A,
11A, Top and front of engine).
WARNING
Always degrease:
-the end of the crankshaft (timing end),
-the timing sprocket bore and bear ing faces,
-the crankshaft accessories pulley bearing
faces,
-the camshaft ends (timing end),
-the camshaft sprocket bores and bear ing faces.
This is to avoid timing slippage.
This slippage leads to engine damage.
111337
111336

13A-5
FUEL SUPPLY
Fuel filter: Removal - Refitting
K9K
13A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the fuel filter mounting nut (3) ,
-the fuel filter from its mounting.
aDetach the water detection sensor offset connector
on the fuel filter mounting (if fitted).
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aaAttach the water detection sensor offset connector
to the fuel filter mounting (if fitted).
aRefit the fuel filter to its mounting.
aFit the fuel filter mounting nut.
II - FINAL OPERATION.
aPosition the fuel pipes.
aConnect to the fuel filter:
-the manual priming pump outlet pipe,
-the high pressure pump inlet pipe.
aOpen the bleed screw on top of the fuel filter.
aPrime the fuel circuit using a manual priming pump
until the disconnected pipes are filled with fuel.
aClose the bleed screw on top of the fuel filter.
aCheck that there are no fuel leaks.
aStart the engine.
aCheck that there are no fuel leaks.
aSwitch off the engine.
aRefit the engine cover.
BLEEDING
aRemove the fuel filter mounting nut.
aDetach the manual priming pump.
aRemove the fuel filter without pulling on the water
detection sensor wiring harness in the diesel fuel.
aPosition a container under the fuel filter which has
been removed from its mounting.
aTurn the bleed cap or the water detection sensor in
the diesel fuel (depending on equipment) by no
more than one turn.
aAllow it to flow until diesel fuel appears.
aClose the bleed cap or the water detection sensor
(depending on equipment).
121441
Note:
If the fuel filter is to be reused, fit blanking plugs
to the fuel supply pipes and fuel filter openings,
using the appropriate blanking plug kit, depend-
ing on the engine (see 13B, Diesel injection,
Diesel injection: Precautions for the repair,
page 13B-1) .
WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.
Note:
Chec k that the fuel filter is correctly positioned
and secure on its mounting by shaking it: the fil-
ter must not move.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.

14A-13
ANTIPOLLUTION
Exhaust gas cooler: Removal - Refitting
K9K
14A
II - REFITTING OPERATION FOR PART
CONCERNED
aOn the workbench, refit the following to the intercoo-
ler:
-a new mounting seal on the gearbox side,
-the mounting on the gearbox side,
-the mounting bolts (gearbox side) onto the inter-
cooler without tightening them,
-a new exhaust gas recirculation rigid pipe,
-the bolts of the exhaust gas recirculation rigid pipe
bracket on the cooler without tightening them.
aFit the exhaust gas recirculation assembly onto the
cylinder head.
aAdjust the mounting (gearbox side) and the exhaust
gas recirculation rigid pipe until they are flat against
the cylinder head.
aFit the exhaust gas recirculation unit assembly bolts,
without tightening them.
aTighten the bolts of the mounting (gearbox side) and
of the exhaust gas recirculation rigid pipe on the ex-
haust gas cooler to secure them on the exhaust gas
cooler.
aRemove the exhaust gas recirculation assembly.
aOn the workbench, torque tighten:
-the mounting bolts (gearbox side) on the cooler
(12 N.m),
-the bolts of the exhaust gas recirculation rigid
pipe on the exhaust gas cooler (12 N.m),
-the bolts of the exhaust gas recirculation rigid
pipe bracket (25 N.m).aOn the workbench, refit the following to the intercoo-
ler:
-a new mounting seal on the gearbox side,
-the mounting on the gearbox side,
-the mounting bolts (gearbox side) onto the inter-
cooler without tightening them,
-a new mounting seal on the timing end,
-the mounting on the timing end,
-the mounting bolts (timing end) onto the intercooler
without tightening them.
aFit the exhaust gas recirculation assembly onto the
cylinder head.
aAdjust the two mountings until they are flat against
the cylinder head.
aFit the exhaust gas recirculation unit assembly bolts,
without tightening them.
aTighten the bolts of the two mountings on the ex-
haust gas cooler to immobilise them on the exhaust
gas cooler.
aRemove the exhaust gas recirculation assembly.
aOn the workbench, torque tighten the mounting
bolts on the cooler (12 N.m).
III - FINAL OPERATION
aRefit the exhaust gas recirculation assembly (see
14A, Antipollution, Exhaust gas recirculation as-
sembly: Removal - Refitting, page 14A-15) . K9K, and 718
Note:
The cooler must absolutely be able to move in
relation to the mounting (gearbox side) and to the
exhaust gas recirculation rigid pipe so that it can
be properly adjusted afterwards on the cylinder
head.
K9K, and 740
Note:
The cooler must absolutely be able to move in
relation to its tw o mountings so that it can be
properly adjusted afterwards on the cylinder
head.

19B-10
EXHAUST
Exhaust: Precautions for the repair
19B
Exhaust trunking with 1 bolt
Exhaust trunking with 2 bolts
Fit the exhaust trunking onto the part of the exhaust
system fitted to the vehicle.
Position the pipe onto the lugs (2) inside the exhaust
trunking.
Tighten the exhaust trunking bolt(s) slightly (depending
on the version).
Position the second part of the exhaust system under
the vehicle, fitting it in the exhaust trunking.Position the second exhaust pipe onto the lugs inside
the exhaust trunking.
Check that the two cut marks (3) are aligned (if applica-
ble).
Position the trunking so that there is no risk of contact
between its bolt or bolts and the heat shields.
Torque tighten
-the exhaust trunking nut with 1 bolt (25 N.m) (if fit-
ted),
-the exhaust trunking nuts with 2 bolts (18 N.m) (if
fitted).
Check the following and deal with if necessary:
-no underbody contact between the exhaust system
and the heat shields,
-all of the heat shields are present and secure.
Start the engine.
Check that there are no leaks: deal with any leaks.
95478
119681
Note:
If necessary, use a workshop jack to lift and hold
the heavy and bulky components of the exhaust
system.
99227
Note:
Any damaged heat shields must be replaced.

19B-18
EXHAUST
Catalytic converter: Removal - Refitting
D4F, and 780 or 782
19B
aRemove the exhaust bracket bolts (6) at the catalytic
converter outlet.
aUndo the intermediate pipe clip.
aRemove the intermediate pipe clip.
aRemove the exhaust downpipe.aRemove:
-the side bracket bolts (7) from the engine,
-the side bracket bolts (8) from the catalytic convert-
er,
-the side exhaust bracket from the catalytic convert-
er.
aLoosen the bolts (9) of the catalytic converter lower
bracket on the catalytic converter.
aRemove:
-the bolts (10) of the catalytic converter lower brack-
et on the engine,
-the bolt (11) securing the catalytic converter lower
bracket on the gearbox,
-the catalytic converter lower exhaust bracket.
108817120960

19B-27
EXHAUST
Expansion chamber: Removal - Refitting
K4M
19B
aFit a new sleeve between the expansion chamber
and the silencer (see 19B, Exhaust, Exhaust: Pre-
cautions for the repair, page 19B-8) .
aTighten the sleeve while supporting the exhaust pipe
to ensure they are aligned.
aCheck:
-that all the exhaust pipe heat shields are in place
and properly attached.
-that there is no contact with the underbody,
-that there are no leaks.WARNING
Position the « nut and bolt securing the sleeve »
assembly so that the assembly cannot come into
contact with the underbody.

19B-32
EXHAUST
Silencer: Removal - Refitting
K4M
19B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aCut the exhaust pipe (see 19B, Exhaust, Exhaust:
Precautions for the repair, page 19B-8) in the des-
ignated area to be cut (see ) .aUnclip the silencer from the rubber mounting bush at
(1) .
aRemove the silencer.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit the silencer.
aClip the silencer onto the rubber mounting bush.
aFit a new sleeve between the expansion chamber
and the silencer (see 19B, Exhaust, Exhaust: Pre-
cautions for the repair, page 19B-8) .
aTighten the sleeve while supporting the exhaust pipe
to ensure they are aligned.
II - FINAL OPERATION.
aCheck:
-that all the exhaust pipe heat shields are in place
and properly attached.
-that there is no contact with the underbody,
-that there are no leaks. IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 19B, Exhaust, Exhaust: Precautions
for the repair, page 19B-8) .
IMPORTANT
Wear heat protective gloves during the operation.
WARNING
To prevent the surrounding components from over-
heating, do not damage (tear, pierce bend etc.) a
heat shield.
All damaged heat shields must be replaced.
131775
IMPORTANT
Position the « nut and bolt securing the sleeve »
assembly so that the assembly cannot come into
contact with the underbody.