2009 RENAULT TWINGO cooling

10A-84
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
D4F or D7F
10A
aRefit:
-the air conditioning pipe bolt on the dehydrator res-
ervoir,
-the air conditioning pipe bolts on the compressor.
aTighten:
-the air conditioning pipe bolts on the dehydrator
reservoir,
-the air conditioning pipe bolts on the compressor.
aFill the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).
aConnect:
-the petrol vapour rebreathing solenoid valve con-
nector,
-the brake servo pipe on the brake servo,
-the heater matrix hoses.
aFit the cooling unit.
aRefill:
-the engine oil, if necessary (see 10A, Engine and
cylinder block assembly, Engine oil: Draining -
Refilling, page 10A-22) ,
-the gearbox oil (see Manual gearbox oils: Drain-
ing - Filling) ,
-and bleed the cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) .
aRefit:
-the air filter unit air inlet pipe,
-the air filter unit air inlet pipe bolt on the cross
member.
aConnect the air filter box air inlet pipe on the air filter
box cover.
aRefit the turbocharger outlet air pipe.
aPush the intercooler air inlet pipe clip.
aConnect the intercooler air inlet pipe on the inter-
cooler.aPush the turbocharger outlet air pipe clip, following
the direction shown by the arrow (23) .
aConnect the turbocharger air outlet pipe onto the tur-
bocharger.
aRefit the turbocharger outlet rigid air pipe bolt on the
throttle valve.
aConnect the intercooler air outlet pipe to the inter-
cooler.
aTighten the intercooler air outlet pipe clip.
aRefit:
-the cooling radiator upper bolts.
-the air filter unit air inlet pipe,
-the air filter box air inlet pipe on the cross member,
aPosition the expansion bottle.
aRefit the expansion bottle bolt.
aClip the bonnet opening release cable on to the cool-
ing fan assembly.
aPosition the earth straps.
aRefit the earth strap nuts on the front right-hand side
member. D4F, and 780 or 782
122666
D4F or D7F, and 772

10A-87
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K9K
10A
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see Sequential gearbox oil: Drain-
ing - Filling) (21A, Manual gearbox),
-the engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the engine, if necessary (see 10A, Engine and
cylinder block assembly, Engine oil: Draining -
Refilling, page 10A-22) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning) (if fitted).
aLoosen the clip (5) on the intercooler air outlet pipe.
aPull the clip (6) of the intercooler air inlet pipe.
aDisconnect:
-the intercooler air outlet pipe,
-the intercooler air inlet pipe.
aAttach the « engine cooling radiator - condenser -
intercooler » assembly to the front upper cross
member using a safety strap(s).aAttach the « engine cooling radiator - condenser »
assembly to the front upper cross member.
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 radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
-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 front section of the intermediate pipe (see 19B,
Exhaust, Intermediate pipe: Removal - Refit-
ting, page 19B-28) . K9K, and 718
122830
K9K, and 740

10A-94
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K9K
10A
aDetach the « engine cooling radiator - air condition-
ing condenser - intercooler » assembly from the
front upper cross member.
aClip on the clip of the intercooler air inlet pipe.
aConnect:
-the intercooler air outlet pipe,
-the intercooler air inlet pipe.
aTighten the clip on the intercooler outlet pipe.
aDetach the « engine cooling radiator - condenser »
assembly from the front upper cross member.
aRefit:
-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 diesel injection computer (see 13B, Diesel in-
jection, Diesel injection computer: Removal -
Refitting, page 13B-13) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the non-return valve pipe on the vacuum pump.aClip:
-the turbocharger regulation solenoid valve wiring,
-the turbocharger regulation solenoid valve pipes.
aConnect:
-the turbocharger regulation solenoid valve connec-
tor,
-the turbocharger regulation solenoid valve pipes.
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
aRefit:
-the air pipe at the air filter unit inlet,
-the battery (see ) (80A, Battery).
aRefill:
-the gearbox (see Sequential gearbox oil: Drain-
ing - Filling) (21A, Manual gearbox),
-the engine 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) (if fitted),
-the brake fluid reservoir.
aBleed the clutch circuit (see Clutch circuit: Bleed)
(37A, Mechanical component controls). K9K, and 718
K9K, and 740
K9K, and 718

10A-96
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: 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 air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aRemove the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aRemove:
-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 engine undertray,
-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 cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, page 19A-9) ,
-the engine, if necessary (see 10A, Engine and
cylinder block assembly, Engine oil: Draining -
Refilling, page 10A-22) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aAttach the « engine cooling radiator - condenser »
assembly to the front upper cross member.
aRemove:
-the engine tie-bar (see 19D, Engine mounting,
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 radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
-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 seal (see Differential output
seal: Removal - Refitting) (21A, Manual gear-
box).
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) . Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Equipment required
refrigerant charging station
Tightening torquesm
rubber pad mounting
bolts for the suspended
engine mounting on the
gearbox21 N.m
bolts of the suspended
mounting r ubber pad62 N.m
suspended engine
mounting shaft nut62 N.m

10A-99
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aDisconnect:
-the engine cooling fan assembly resistor connector
(16) ,
-the engine cooling fan assembly connector (17) .
aUnclip:
-the engine cooling fan assembly wiring at (18) ,
-the cooling radiator top and bottom hose from the
engine cooling fan assembly.aRemove:
-the engine compartment connection unit cover
bolts (19) ,
-the cover of the engine compartment connection
unit.
aDisconnect the connector (20) from the engine com-
partment connection unit.
aRemove the engine compartment connection unit
nuts (21) from the body.
aMove the engine compartment connection unit to
one side.
132336121429
121213

10A-103
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
-the rubber pad mounting from the suspended en-
gine mounting on the gearbox.
aRemove the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aLift the vehicle to remove the "engine and gearbox"
assembly.
REFITTING
I - REFITTING PREPARATION OPERATION
aFor standard engine replacement (see Standard re-
placement) (Technical Note 6023A, 10A, Engine
and peripherals).
II - REFITTING OPERATION
aPosition the "engine and gearbox" assembly in the
body.
aRefit the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aRefit the rubber pad mounting from the suspended
engine mounting on the gearbox.
aTorque tighten the rubber pad mounting bolts for
the suspended engine mounting on the gearbox
(21 N.m).
aRefit the suspended engine mounting rubber pad.
aTorque tighten:
-the bolts of the suspended mounting rubber
pad (62 N.m),
-the suspended engine mounting shaft nut (62
N.m).
III - FINAL OPERATION
aRemove the.
aRemove the blanking plugs.
aConnect:
-the union of the brake servo vacuum pipe,
-the « compressor - condenser » connecting pipe,-the « compressor - intermediate pipe » connecting
pipe,
-the pressure sensor connector,
aConnect the hose on the coolant pump inlet pipe.
aFit the hose clip on the coolant pump inlet pipe using
the (Mot. 1448).
aRefit the earth nuts.
aClip:
-the relay plates on the engine compartment con-
nection unit,
-the fuse holders.
aConnect the fuses.
aRefit the engine compartment connection unit on the
body.
aConnect the connector to the engine compartment
connection unit.
aRefit the engine compartment connection unit cover.
aClip:
-the wiring on the engine cooling fan assembly,
-the cooling radiator top and bottom hoses on the
engine cooling fan assembly.
aConnect:
-the engine cooling fan assembly resistor connec-
tor,
-the engine cooling fan assembly connector.
aRemove the blanking plug from the fuel supply pipe
opening and the injector rail fuel opening.
aReconnect the fuel supply pipe.
aClip the fuel supply pipe in place.
aConnect:
-the fuel vapour absorber bleed solenoid valve con-
nector,
-the fuel vapour absorber bleed solenoid valve pipe.
aFit the gearbox control cables.
aClip the manual gearbox control cables onto:
-the gear selectors,
-the cable sleeve stops.
aRemove the blanking plug from the hydraulic clutch
control pipe opening and the opening of the clutch
thrust bearing.
aConnect the hydraulic clutch control pipe.
aClip the hydraulic clutch control pipe on the gearbox. Note:
Check no component obstructs the movement of
the body around the engine - gearbox assembly.

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