2009 RENAULT TWINGO Engine And Peripherals Workshop Manual

12A-56
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K4M
12A
aRemove:
-the bulkhead heat shield bolts (2) ,
-the bulkhead heat shields.
aDisconnect the oxygen sensor connectors (3) .
aUnclip the oxygen sensor wiring at (4) .
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12A-57
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K4M
12A
II - REMOVAL OPERATION
aRemove the exhaust manifold nuts.
aRemove:
-the bolts (5) from the « exhaust manifold - catalytic
converter » assembly,
-the « exhaust manifold - catalytic converter » as-
sembly,
-the seal from the « exhaust manifold - catalytic
converter » assembly.
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132392
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12A-58
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K4M
12A
If replacing the « exhaust manifold - catalytic
converter » assembly
aRemove:
-the upstream and downstream oxygen sensors (6)
,
-the heat shield (7) .
REFITTING
I - REMOVAL PREPARATION OPERATION
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the exhaust manifold joint face if it is to be re-used,
-the cylinder head joint face.
aparts always to be replaced: exhaust manifold
seal.
aTorque tighten the exhaust manifold studs (9
N.m).If replacing the « exhaust manifold - catalytic
converter » assembly
aClean the threading of the upstream and down-
stream oxygen sensors using a wire brush.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the thread holes of the upstream and downstream
oxygen sensors on the exhaust manifold,
-the threading of the upstream and downstream ox-
ygen sensors.
aRefit the heat shield.
aTighten:
-to torque and in order the heat shield bolts (12
N.m),
-to torque the upstream and downstream oxygen
sensors ( 44 N.m).
aIf the strut mounting bolt on the cylinder block be-
comes loose, torque tighten the strut mounting
bolt on the cylinder block ( 75 N.m).
II - REFITTING OPERATION
aRefit:
-a new seal on the « exhaust manifold - catalytic
converter » assembly,
-the « exhaust manifold - catalytic converter » as-
sembly.
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Note:
If a stud loosens during removal, coat it with
HIGH RESISTANCE THREADLOCK (see Vehi-
cle: Parts and consumables for the repair)
(04B, Consumables - Products).
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12A-59
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K4M
12A
aPretighten the upstream strut bolt (initial torque)
(14 N.m) (8) .
aTorque tighten in order the exhaust manifold nuts
(26 N.m).aTorque tighten the upstream and downstream
(strut bolts44 N.m) (9) .
aTorque tighten the upstream strut bolts (44 N.m)
(10) .
III - FINAL OPERATION
aClip on the oxygen sensor wiring.
aConnect the oxygen sensor connectors.
aRefit:
-the bulkhead heat shields,
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12A-60
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
K4M
12A
-the driveshaft relay bearing.
aTorque tighten the driveshaft relay bearing bolts
(21 N.m).
aRefit:
-the upstream expansion chamber (see 19B, Ex-
haust, Expansion chamber: Removal - Refit-
ting, page 19B-23) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts).
aFill the gearbox (see Manual gearbox oils: Drain-
ing - Filling) (21A, Manual gearbox).
aRefit:
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (85A, Wiping -
Washing),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the engine undertray.
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).

12B-1
TURBOCHARGING
Turbocharging: Precautions for the repair
D4F or K9K
12B
I - TURBOCHARGER: GENERAL INSTRUCTIONS
For the turbocharging pressure regulator check (see
Fault finding - Tests) (Technical Note 3419A, 12B,
Turbocharging).
II - TURBOCHARGER CIRCUIT DIAGRAMIII - APPLICATION CONDITIONS OF
INSTRUCTIONS
The instructions below must be followed when repla-
cing a turbocharger due to mechanical damage:
-damage to the bearing system,
-broken shaft or turbine wheel,
-compressor wheel rubbing against the turbocharger
casing,
-broken or damaged compressor wheel,
-extensive clogging of the turbine wheel casing (hard
deposits).
FOR THE AIR CIRCUIT:
-Consequences:
•swarf or metal objects in the turbocharger inlet and
outlet pipes,
•oil in the air circuit (collected in the intercooler).
-Risks (after replacing the turbocharger):
•metal objects sucked in by the compressor wheel
(destruction of the turbocharger).
FOR THE LUBRICATION CIRCUIT:
-Consequences:
•swarf found in the engine oil circuit,
•circulation of swarf within the circuit.
-Risks (after replacing the turbocharger):
•premature wear on the bearing system (destruction
of turbocharger).
INSTRUCTIONS:
-Drain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22)
-Replace the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29) .
-Replace the seals and fittings,
-Carry out the following only if the compressor wheel is
broken or rubbing against the turbocharger casing:
•Drain the intercooler, Equipment required
par ts washer
WARNING
The turbocharger pressure regulator rod must not
be adjusted.
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(1) Air filter unit
(2) Air flowmeter
(3) Compressor wheel
(4) Intercooler
(5) Inlet distributor
(6) Exhaust manifold
(7) Turbine wheel
(8) Bearing system (bearing +
wheel shaft)
(A) Air filter box air outlet pipe
(B) Turbocharger air outlet pipe
(C) Intercooler air outlet pipe
WARNING
Metal objects may enter the oil and air circuits as a
result of a broken turbocharger.
Failure to follow the INSTRUCTIONS listed will lead
to the turbocharger breaking again.

12B-2
TURBOCHARGING
Turbocharging: Precautions for the repair
D4F or K9K
12B
•Clean the turbocharger air pipes.
IV - AIR CIRCUIT*: INSTRUCTIONS FOLLOWING
MECHANICAL DAMAGE TO THE TURBOCHARGER
Remove the intercooler if fitted to the vehicle (see 12B,
Turbocharging, Intercooler: Removal - Refitting,
page 12B-18) .
Turn the intercooler over and allow the oil inside to
drain out.Check that there are no metal objects inside the air
flowmeter (2) .
Remove:
-the air pipe(between the air filter unit and the turbo-
charger) (A) ,
-the air pipe (B) (between the turbocharger and the in-
tercooler).
For air pipes comprising several components:
-mark (10) the fitting position of each component,
-separate all the components. Note:
When carrying out an oper ation on the air or lubri-
cation circuit, it is necessary to plug the open holes
to prevent any risk of foreign bodies entering the
system.
Note:
(*) These instructions for the air circuit are only to
be followed in the case of:
-broken compressor wheel,
-compressor wheel rubbing against the turbo-
charger casing.
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Note:
If the compressor wheel (9) is damaged, metal
objects are ejected inside the air pipes.
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112770

12B-3
TURBOCHARGING
Turbocharging: Precautions for the repair
D4F or K9K
12B
One by one, clean the pipes removed with the parts
washer :
-brush as much of the inside of the pipe as possible
(only use brushes with plastic bristles),
-wash plenty of cleaning product from the cleaning sta-
tion through the pipe,
-allow the cleaned pipe to drain by standing it upright,
-ensure the cleaning product has drained out com-
pletely (check areas where liquid may be retained,
e.g. gaiters, resonators etc.).
Dry the pipes one by one using a compressed air spray
gun.
For pipes comprising several components:
-assemble the components, taking note of their correct
fitting position (10) .
Refit:
-the air pipe(between the air filter unit and the turbo-
charger) (A) ,
-the air pipe (B) (between the turbocharger and the in-
tercooler).
Refit the intercooler, if fitted to the vehicle (see 12B,
Turbocharging, Intercooler: Removal - Refitting,
page 12B-18) .V - LUBRICATION CIRCUIT**: INSTRUCTIONS
FOLLOWING MECHANICAL DAMAGE TO THE
TURBOCHARGER
Drain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) .
Replace the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting, page
10A-29) .
Only fill the engine with a suitable oil type (see Engine
oil: Specifications) (Technical Note 6013A, 04A, Lu-
bricants).
VI - GENERAL INSTRUCTIONS TO BE FOLLOWED
WHEN REMOVING A TURBOCHARGER
Always replace:
-the oil supply pipe:
•if the pipe is blocked, even partially (due to scale,
carbonised oil etc.),
•if the pipe is fitted with self-retaining seals.
-the oil return pipe:
•if the pipe is blocked, even partially (due to scale,
carbonised oil etc.),
•if the pipe is fitted with self-retaining seals.
-all seals that have been removed,
-all fittings that have been removed.
When starting the engine:
-do not accelerate,
-allow the engine to run for 1 minute,the time taken for
the oil circuit pressure to increase (until the oil pres-
sure warning light on the instrument panel goes out),
-accelerate several times at no load,
-check the air circuit and the oil circuit for leaks.
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Note:
(**) These instructions relating to the lubrication cir-
cuit must always be followed in all cases of
mechanical damage as listed above.
WARNING
Failure to observe the following procedure may lead
to destr uction of the turbocharger.