2009 RENAULT TWINGO cooling

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 ".

10A-56
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil pump: Removal - Refitting
D4F or D7F
10A
aRemove:
-the nut,
-the cover,
-the guard,
-the threaded rod.
aConnect the oil-coolant heat exchanger hoses.
aPut the clips (3) in place using the (Mot. 1448).
aRemove the hose clamps (Ms. 583) from the oil-wa-
ter heat exchanger hoses.
aConnect the oil pressure sensor connector.
aRefit:
-the timing sprocket,
-the sump (see 10A, Engine and cylinder block
assembly, Lower cover: Removal - Refitting,
page 10A-6) .
aFit the lower engine support tool (Mot. 1379).
aRemove:
-the right-hand suspended mounting support bolts,
-the right-hand suspended mounting support,
-the upper timing cover bolts,
-the upper timing cover.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 right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) .
aRemove the lower engine support tool (Mot. 1379).
aRefit:
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the engine undertray,
-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 dipstick,
-the oil filter (see 10A, Engine and cylinder block
assembly, Oil filter: Removal - Refitting, page
10A-29) .
aTop up the engine oil (see 10A, Engine and cylin-
der block assembly, Engine oil: Draining - Refill-
ing, page 10A-22) .
aTop up the coolant level (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
20779
D4F, and 780 or 782

10A-60
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil pressure: Check
D4F or D7F or K9K
10A
aPosition the engine oil pressure sensor tool (Mot.
836-05) fitted with suitable end pieces using the
(Mot. 1495-01) or a 1/2" long socket (12.7 mm
square drive).
aEnd pieces:
-D4F and D7F engines:
•end piece C + F
-K9K engine:
•end piece E + C + F
aStart the vehicle.
aMonitor the engine oil pressure as the engine oil
temperature increases (approximately 80˚C or the
first time the engine cooling fan is triggered)
which must not be lower than the pressure at idle
speed.
aIf the oil pressure is lower at idle speed, check that:
-the oil filter is not clogged,
-there is no dirt or swarf in the engine oil,
-the oil pump is in good condition and being correct-
ly driven.
aCheck the oil pressure at 3000 rpm.
aCheck the values:
-D4F and D7F engines:
•Idling: 0.8 bar
•3000 rpm: < 3.5 bars
-K9K engine•idling: 1.2 bar
•3000 rpm: < 3.5 bars
aSwitch off the engine.
aRemove the (Mot. 836-05) with the end pieces.
aRefit the oil pressure sensor (see 10A, Engine and
cylinder block assembly, Oil pressure sensor:
Removal - Refitting, page 10A-45) .
aWipe any oil run-off with a cloth.
aWait at least 10 minutes.
aCheck the oil level using the dipstick.
aTop up the engine oil level if necessary.
aStart the vehicle and check that there are no oil
leaks at the oil pressure sensor.
87363

10A-61
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil pressure: Check
K4M
10A
Oil pressure tables:
End pieces to be used:
I - REMOVAL PREPARATION OPERATION
a
II - CHECK
aRemove the oil pressure sensor (see 10A, Engine
and cylinder block assembly, Oil pressure sen-
sor: Removal - Refitting, page 10A-45) .aIn place of the oil pressure sensor, fit the (Mot. 836-
05) with suitable adapters using the (Mot. 1495-01)
or a 22 mm long socket.
aStart the vehicle.
aMonitor the engine oil pressure as the oil tempera-
ture rises (approximately 80˚C or the first time the
engine cooling fan is activated); it should not be less
than the pressure at idle speed.
aIf the oil pressure is lower than the pressure at idle
speed, check that:
-the oil filter is not clogged,
-dirt or swarf is not present in the engine oil,
-the oil pump is in good condition and being correct-
ly driven. Special tooling required
Mot. 836-05Oil pressure gauge kit.
Mot. 1495-0122 mm socket for removal -
refitting of oxygen sensors.
Engine Engine suffixMinimum oil pressure (bar) Maximu m o i l
pressure (max)
Idling speed 4000 rpm 4000 rpm
K4M 8540.5 3.1 4.4
Engine End pieces
K4M E+C+F
WARNING
Always check the oil level using the dipstick.
Do not exceed the maximum level on the dipstick
(could destroy the engine).
Correct the engine oil level if necessary before
delivering the vehicle to the customer.
Note:
When topping up the engine oil, always leave at
least 10 minutes before checking the level with a
dipstick.
87363

10A-69
ENGINE AND CYLINDER BLOCK ASSEMBLY
Multifunction support: Removal - Refitting
D4F, and 780 or 782
10A
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 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 alternator (see 16A, Starting - Charging, Al-
ternator: Removal - Refitting, page 16A-1) .
aRemove the air conditioning compressor (see Com-
pressor: Removal - Refitting) (62A, Air condition-
ing).II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the bolt of the coolant-oil heat exchanger cooling
pipes support from the multifunction support,
-the bolts (4) from the coolant pump inlet pipe,
-the multifunction support bolts (3) ,
-the multifunction support.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the multifunction support,
-the multifunction support bolts,
-the coolant pump inlet pipe bolts,
-the bolt of the coolant-oil heat exchanger cooling
pipes support on the multifunction support.
aTorque tighten:
-the multifunction support bolts (50 N.m),
-the coolant pump inlet pipe bolts (10 N.m). Tightening torquesm
multifunction support
bolts50 N.m
coolant pump inlet pipe
bolts10 N.m
AIR CONDITIONING
120956

10A-76
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
D4F or D7F
10A
aRemove the bolt (4) from the expansion bottle.
aMove the expansion bottle aside following the ar-
rows (5) and (6) .
aRemove:
-the air filter box air inlet pipe from the cross mem-
ber,
-the air filter unit air inlet pipe,
-the cooling radiator upper bolts. JH3
120514
D4F or D7F, and 772

10A-77
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
D4F or D7F
10A
a
aUndo the clip from the intercooler outlet pipe.
aDisconnect the intercooler outlet air pipe.
aRemove the turbocharger air outlet rigid pipe bolt (9)from the throttle valve.
aDetach the turbocharger air outlet pipe from the tur-
bocharger in the direction of the arrow (10) .
aDisconnect the turbocharger air outlet pipe from the
turbocharger.
aUnclip the intercooler air inlet pipe.
aDisconnect the intercooler air inlet pipe from the in-
tercooler.
aRemove the turbocharger air outlet pipe.
aDisconnect the air filter box air inlet pipe from the air
filter box cover (12) .
aRemove:
-the air filter unit air inlet pipe bolt from the cross
member (13) ,
-the air filter unit air inlet pipe.
aDrain:
-the cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, page 19A-9) ,
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-the engine if necessary (see 10A, Engine and cyl-
inder block assembly, Engine oil: Draining - Re-
filling, page 10A-22) .
aAttach the cooling unit to the engine.
aDisconnect:
-the heater matrix hoses,
-the brake servo pipe on the brake servo,
-the petrol vapour rebreathing solenoid valve con-
nector,
-the petrol vapour rebreather pipe. D4F, and 780 or 782
122833
122673
Note:
If the turbocharger outlet air pipe tightening clip
(7) is removed, the rubber flexible pipe (8) and
the tightening clip (7) must be replaced.
Note:
If the clip (11) is removed from the heat resistant
protector, the latter must be replaced.