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

© Renault s.a.s 2007 "The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are
constructed".All rights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part reference
numbering system is forbidden without the prior written authority of Renault.
NOVEMBER 2009 EDITION ANGLAISE
X44
19ACOOLING
19BEXHAUST
19CTANK
19DENGINE MOUNTING

Contents
13C PREHEATING
Pre-postheating unit:
Removal - Refitting 13C-1
Heater plugs: Removal -
Refitting 13C-2
14A ANTIPOLLUTION
Oil vapour rebreathing
circuit: Descriptions 14A-1
Fuel vapour recirculation
circuit: Operating diagram 14A-2
Fuel vapour recirculation
circuit: Check 14A-3
Fuel vapour absorber:
Removal - Refitting 14A-4
Fuel vapour absorber: Check 14A-7
Fuel vapour absorber bleed
solenoid valve: Removal -
Refitting 14A-8
Exhaust gas recirculation
solenoid valve: Removal -
Refitting 14A-10
Exhaust gas cooler: Removal
- Refitting 14A-11
Exhaust gas recirculation
assembly: Removal -
Refitting 14A-15
Exhaust gas recirculation
rigid pipe: Removal -
Refitting 14A-19
16A STARTING - CHARGING
Alternator: Removal -
Refitting 16A-1
Star ter: Removal - Refitting 16A-10
Alternator pulley: Removal -
Refitting 16A-1717A IGNITION
Coils: Removal - Refitting 17A-1
Plugs: Removal - Refitting 17A-12
17B PETROL INJECTION
Petrol injection: List and
location of components 17B-1
Oxygen sensors: Removal -
Refitting 17B-13
Petrol injection computer:
Removal - Refitting 17B-20
Pinking sensor: Removal -
Refitting 17B-23
Crankshaft position sensor:
Removal - Refitting 17B-25
Injector rail - Injectors:
Removal - Refitting 17B-27
19A COOLING
Engine cooling system:
Specifications 19A-1
Engine cooling system:
Check 19A-2
Engine cooling circuit: List
and location of components 19A-4
Engine cooling system:
Operating diagram 19A-5
Cooling system: Draining -
Refilling 19A-9
Cooling radiator: Removal -
Refitting 19A-12
Coolant pump: Removal -
Refitting 19A-24
Thermostat: Removal -
Refitting 19A-34
Water chamber: Removal -
Refitting 19A-40

Contents
Engine cooling fan assembly:
Removal - Refitting 19A-51
Coolant pump inlet pipe:
Removal - Refitting 19A-58
Expansion bottle: Removal -
Refitting 19A-64
Coolant temperature sensor:
Removal - Refitting 19A-66
19B EXHAUST
Exhaust: List and location of
components 19B-1
Exhaust: Precautions for the
repair 19B-8
Catalytic converter: Removal
- Refitting 19B-12
Expansion chamber :
Removal - Refitting 19B-23
Intermediate pipe: Removal -
Refitting 19B-28
Silencer : Removal - Refitting 19B-31
19C TANK
Fuel tank: Draining 19C-1
Fuel tank: Removal -
Refitting 19C-4
Filler neck: Removal -
Refitting 19C-11
Fuel level sensor module:
Removal - Refitting 19C-13 19A COOLING
19D ENGINE MOUNTING
Suspended engine
mounting: Tightening torque 19D-1
Left-hand suspended engine
mounting: Removal -
Refitting 19D-4
Right-hand suspended
engine mounting: Removal -
Refitting 19D-13
Lower engine tie-bar:
Removal - Refitting 19D-18

10A-3
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal, gearbox end: 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 and gearbox » assembly (see 10A,
Engine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) ,
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) (21A, Manual gearbox).
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch),
-the flywheel (see 10A, Engine and cylinder block
assembly, Flywheel: Removal - Refitting, page
10A-107) . Special tooling required
Mot. 1129-01Tool for fitting the crankshaft
seal, flywheel end (80 x 100 x
8 seal).
Equipment required
refrigerant charging station

10A-5
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal, gearbox end: Removal - Refitting
K4M
10A
-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).
aRefill:
-and bleed the engine cooling circuit (see 19A,
Cooling, Cooling system: Draining - Refilling,
page 19A-9) ,
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aRefit the engine undertray.

10A-15
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
D4F or D7F
10A
aAttach the cooling radiator to the upper cross mem-
ber.
aRemove:
-the bolts (6) from the front end cross member,
-the subframe bolts (7) .
aRemove the threaded rods of the (Tav. 1233-01)
one by one, replacing them with the subframe
mounting bolts.
aLower the subframe by several centimetres, gradu-
ally loosening the nuts of the (Tav. 1233-01).II - OPERATION FOR REMOVAL OF PART
CONCERNED
1 - Removing the sump with silicone adhesive
sealant
aRemove the sump bolts.
aGradually remove the sump using the (Mot. 1716).
aRemove the sump by pivoting it anti-clockwise to
prevent catching the oil pump strainer.
2 - Removing the sump with an After-Sales seal
aRemove:
-the sump bolts,
-the sump by pivoting it anti-clockwise to prevent
catching the oil pump strainer,
-the sump seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: engine oil sump
seal.
aUse SUPER CLEANING AGENT FOR JOINT FA-
CES (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to clean
the joint faces:
-of the cylinder block,
-of the sump.
aLeave for approximately ten minutes.
aRemove the residue using a wooden spatula.
aFinish cleaning the parts using a GREY ABRASIVE
PAD (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products).
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease the joint fa-
ces:
-of the cylinder block,
-of the sump.
119336
Note:
This operation requires two people.
Note:
Make sure the threaded rod of the (Tav. 1233-01)
is sufficiently screwed into the threaded hole and
that the nut of the tool is properly resting on the
subframe.
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).

10A-33
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil-coolant heat exchanger: Removal - Refitting
K9K
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the engine cover,
-the front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection).
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aRemove the expansion bottle bolt.
aRemove the expansion bottle.
aUnclip the cooling hose on the lower section of the
engine cooling fan.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect:
-the cooling hose (1) using the (Mot. 1448),
-the oil pressure sensor connector (2) .
aRemove:
-the bolt (3) from the oil filter support,
-the oil filter holder.
aRemove:
-the oil cooler nipple,
-the oil-water heat exchanger. Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
121432
Note:
Be prepared for engine oil and coolant to flow
out.

10A-34
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil-coolant heat exchanger: Removal - Refitting
K9K
10A
REFITTING
I - REFITTING PREPARATION OPERATION
aUsing the buffing pads, clean the pressure faces of
the oil-water heat exchanger and the cylinder block.
aFit new seals on the oil-water heat exchanger with
soapy water.
aCheck the condition of the oil-water heat exchanger
nipple seals.
II - REFITTING OPERATION FOR PART
CONCERNED
aCoat the nipple with high resistance thread lock.
aRefit:
-the coolant-oil heat exchanger,
-the oil-coolant heat exchanger nipple.
aFit a new seal on the oil filter holder.
aRefit:
-the oil filter holder,
-the oil filter mounting bolt.
aTighten the oil filter mounting bolt.
aConnect:
-the oil pressure sensor connector,
-the cooling hose using the (Mot. 1448).
III - FINAL OPERATION
aClip the cooling hose on to the lower section of the
engine cooling fan.
aPosition the expansion bottle.
aRefit the expansion bottle bolt.aFill the cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, page 19A-9) .
aRefit:
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the engine cover. WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).
WARNING
The gaskets must always be replaced with new
gaskets.
Note:
The oil-water heat exchanger nipple seals cannot
be separated; the entire assembly must be
replaced.

10A-36
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil-coolant heat exchanger: Removal - Refitting
D4F, and 780 or 782
10A
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: coolant-engine oil
heat exchanger seal on the cylinder block.
aUse a GREY ABRASIVE PAD (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) to clean the bearing faces of the
oil-coolant heat exchanger and the cylinder block.
II - REFITTING OPERATION FOR PART
CONCERNED
aCoat the nipple with HIGH STRENGTH THREAD-
LOCK (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products).
aRefit:
-the oil-coolant heat exchanger,
-the oil-coolant heat exchanger nipple.
aTorque tighten the oil-coolant heat exchanger nip-
ple (30 N.m).
aConnect the oil-coolant heat exchanger hoses.
aRefit the clips using the (Mot. 1448).
aRemove the tools (Ms. 583).
III - FINAL OPERATION
aRefit:
-the 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).
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) . WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

10A-41
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
a
Pull the con rod - piston assembly using the tie rod of
the tool (Mot. 1914), taking care not to allow the pis-
ton to touch the piston base cooling jets.
aRemove the upper con rod bearing shell.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - products) to clean the bearing mating face on
the con rod body.
REFITTING
I - REFITTING OPERATION FOR THE CON ROD
BEARING SHELLS ON CYLINDER NO.2
aparts always to be replaced: con rod cap boltsa
Fit the head of the tool (Mot. 1920) with the marking
" K9K INF " on the threaded sleeve of the tool (Mot.
1914).
aPosition the lower con rod bearing shell on the tool
(Mot. 1920).
139315
WARNING
Failure to observe the following procedure may
damage the piston base cooling jets.
Note:
If reusing the con rod bearing shells, mark the
position of the upper con rod bearing shell in
relation to the con rod body.
Note:
Always replace con rod bearing shells with a
width of 20 mm by con rod bearing shells with a
width of 18 mm.
If the set of con rod bearing shells only includes
con rod bearing shells which are 18mm wide,
only use the head of the tool (Mot. 1920) with the
mar king " K9K SUP ".