2009 RENAULT TWINGO RS brake

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.

11A-66
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D7F
11A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery ( (see Battery: Removal -
Refitting) ).
aRemove:
-the intake distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
aUnclip:
-The harness from the heat shield,
-the brake servo pipe from the heat shield.
aDisconnect the ignition coil supply.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the rocker cover bolts,
-the rocker cover.ON THE WORKBENCH
aRemove:
-the ignition coil,
-the heat shield.
REFITTING
I - REFITTING PREPARATIONS OPERATION
ON THE WORKBENCH
aRefit:
-the heat shield,
-the ignition coil.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the rocker cover,
-the rocker cover bolts.
aTorque tighten the rocker cover bolts (10 Nm).
III - FINAL OPERATION.
aConnect the ignition coil supply.
aClip:
-the brake servo pipe onto the heat shield,
-the harness onto the heat shield.
aRefit:
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the intake distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) .
aConnect the battery ( (see Battery: Removal - Re-
fitting) ). Tightening torquesm
rocker cover bolts10 Nm
110422

11A-73
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 780 or 782 or 784
11A
aDisconnect the oil vapour rebreathing circuit unions
(9) .
-on the inlet distributor,
-on the air filter box outlet air pipe,
-on the rocker cover.
aRemove the oil vapour rebreathing circuit.
aDisconnect the fuel vapour rebreathing circuit
unions (10) .
-on the air filter box outlet air pipe,
-to the inlet distributor.
aMove the fuel vapour rebreathing pipes to one side.
aDisconnect the vacuum pipe from the brake servo
(11) .
aMove the brake servo vacuum pipe to one side.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the rocker cover bolts,
-the rocker cover,
-the rocker cover gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
aClean the joint faces with SUPER CLEANER FOR
JOINT FACES (see Vehicle: Parts and consum-
ables for the repair) (04B, Consumables - Prod-
ucts) to dissolve any part of the seal still adhering.
aparts always to be replaced: rocker cover seal.
122828
121026
WARNING
Do not allow this product to dr ip onto the paint-
work.
Clean the cylinder head carefully to prevent for-
eign bodies from entering the oil supply and
return galleries.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.

11A-74
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 780 or 782 or 784
11A
II - REFITTING OPERATION FOR PART
CONCERNED
aApply beads (1) of MASTIXO (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) around the rocker cover rear bolts
(lower bolts, exhaust side) and on camshaft bearing
no.5.
aFit the new rocker cover seal, starting with bearing
No. 5, then gradually insert the seal studs as the
rocker cover fits into the groove.aRefit:
-the rocker cover fitted with a new seal,
-the rocker cover bolts.
aPretighten to torque and in order the rocker cover
bolts (initial torque) (5 N.m).
aTorque tighten in order the rocker cover bolts (13
N.m).
III - FINAL OPERATION
aFit the brake servo vacuum pipe.
aConnect the brake servo vacuum pipe.
aFit the fuel vapour rebreathing pipes.
aConnect the fuel vapour rebreathing circuit unions:
-on the inlet distributor,
-on the air filter box outlet air pipe.
aFit the oil vapour rebreathing circuit.
aConnect the oil vapour rebreathing circuit unions:
-on the rocker cover,
-on the air filter box outlet air pipe,
-to the inlet distributor.
aRefit:
-the ignition coil (see 17A, Ignition, Coils: Remov-
al - Refitting, page 17A-1) ,
-the filler neck,
-the filler neck bolt,
-the heat shield,
-the heat shield bolts.
aTorque tighten the heat shield bolts (8 N.m).
18441
WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
ture of sealant and fluid could damage certain
components (engine, radiator, etc.).
121026

11A-115
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K9K
11A
aFit blanking plugs to the fuel pipes and the high pres-
sure pump (see 13B, Diesel injection, Diesel in-
jection: Precautions for the repair, page 13B-1) .
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aUnclip:
-the breather pipe on the gearbox,
-the wiring on the engine lifting eye on the gearbox
side.
aMove aside the engine wiring.
aDisconnect the brake servo pipe from the vacuum
pump.
aRemove the cooling hose clip from the EGR cooler
using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
aDisconnect the cooling hose from the EGR cooler.
aSeparate the clip on the cooling hose of the coolant
pump inlet pipe using the tool (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
aDisconnect the cooling hose from the coolant pump
inlet pipe.
aRemove the heater matrix cooling hose clip from the
water chamber using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448).
aDisconnect:
-the heater matrix cooling hose from the water
chamber,
-the coolant temperature sensor connector.
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .aRemove:
-the oil return pipe bolts (1) from the turbocharger,
-the oil return pipe by detaching it from the cylinder
block,
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) ,
-the two high pressure pipes between the rail and
injector at the timing end (see 13B, Diesel injec-
tion, High pressure pipe between rail and injec-
tor: Removal - Refitting, page 13B-39) ,
-the timing end bracket bolt from the air filter box,
-the timing end bracket from the air filter box.
112327

11A-117
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K9K
11A
aIf necessary, carry out a complete check of the cylin-
der head (see Cylinder head: Check) .
II - REFITTING OPERATION FOR PART
CONCERNED
aBring the pistons to mid-stroke position to prevent
them from coming into contact with the valves during
the tightening of the cylinder head.
aRefit:
-a new cylinder head gasket,
-the cylinder head.
Cylinder head tightening procedure
aRefit the cylinder head bolts.
aFit the cylinder head bolts, without tightening them.
aTighten to torque and in order the cylinder head
bolts (initial torque) (25 N.m).
aCheck that the cylinder head bolts are tightened to
25 Nm.
aAngle tighten the cylinder head bolts (270˚ ±± ± ±
10˚) in
order using a cylinder head bolt tightening gauge
(angular measuring type).
III - FINAL OPERATION
aRefit:
-the timing end bracket on the air filter box.
-the timing end bracket bolt on the air filter box,-the two high pressure pipes between the rail and
injector at the timing end (see 13B, Diesel injec-
tion, High pressure pipe between rail and injec-
tor: Removal - Refitting, page 13B-39) ,
-the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-66) ,
-the oil return pipe fitted with new seals, fitting it into
the cylinder block (see 12B, Turbocharging, Tur-
bocharger oil pipe: Removal - Refitting, page
12B-12) .
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .
aConnect:
-the coolant temperature sensor connector,
-the heater matrix cooling hose to the water cham-
ber.
aFit the clip on the heater matrix cooling hose onto
the water chamber using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
aConnect the coolant pump inlet pipe cooling hose.
aFit the cooling hose clip at the coolant pump inlet
pipe end using the (Mot. 1202-01) or (Mot. 1202-02)
or (Mot. 1448).
aConnect the EGR cooler cooling hose.
aFit the cooling hose clip at the EGR cooler end using
the (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
aConnect the brake servo pipe onto the vacuum
pump.
aFit the engine wiring.
aClip:
-the breather pipe onto the gearbox,
-the wiring on the engine lifting eye on the gearbox
side.
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
aRemove the blanking plugs from the fuel pipes and
high pressure pump.
aConnect the fuel inlet and return pipes to the high
pressure pump.
aFit the engine wiring.
aConnect:
-the accelerometer connector,
-injector rail pressure sensor connector, WARNING
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.
19712

12A-16
FUEL MIXTURE
Air filter unit: Removal - Refitting
D7F
12A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aParts always to be replaced :
-the air filter.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the anti-interference wire bolt.
aDisconnect the ignition coil connector (1) .
aRemove the ignition coil bolts (2) .
aMove aside the ignition coil.
aRemove the air filter box cover (3) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect:
-the non-return valve pipe on the brake servo,
-the petrol vapour rebreather pipe union from the in-
take distributor.
aMove aside the air filter box air inlet duct.
aUndo the air filter box air outlet duct clip.
aRemove the air filter box air outlet duct.
aUnclip the air filter box elastic straps.
aRemove:
-the air filter box,
-the air filter from the air filter unit.
REFITTING
I - REFITTING PREPARATIONS OPERATION
If reusing the air filter box
aUse a compressed air nozzle to clean the air filter
housing to get rid of any foreign bodies.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the air filter box fitted with a new seal.
aClip on the air filter box elastic straps.
aRefit the air filter box air outlet duct.
aTighten the air filter box air outlet duct clip.
aRefit the air filter box air inlet duct.
aConnect:
-the non-return valve pipe on the brake servo,
-the petrol vapour rebreather pipe union from the in-
take distributor.
III - FINAL OPERATION.
aFit the ignition coil.
aRefit the ignition coil bolts.
aConnect the connector of the ignition coil.
aRefit the anti-interference wire bolt. Equipment required
compressed air nozzle
120404

12A-34
FUEL MIXTURE
Inlet distributor: Removal - Refitting
D4F, and 772
12A
aDisconnect:
-the oil vapour rebreathing pipe from the inlet dis-
tributor (2) ,
-the non-return valve pipe on the brake servo (3) ,
-the petrol vapour rebreather pipe from the inlet dis-
tributor (4) ,
-the air inlet pressure sensor connector (5) ,
-the inlet air temperature sensor connector (6)
-the throttle valve connector (7) ,
-the injector connectors (8) .
aDisconnect:
-the spark plug high voltage wiring harnesses (9) ,
-the fuel supply pipe union on the injector rail.
aUnpick the engine wiring from the inlet distributor.
aRemove the dipstick.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the nuts (10) from the inlet distributor on the rocker
cover,
-the inlet distributor bolts from the cylinder head,
-the inlet distributor.
When replacing the inlet distributor
aUsing the workbench, remove:
-the fuel supply pipe to the injector rail,
-the injector rail bolts,
-the throttle valve bolts,
-the throttle valve.
121733
WARNING
To disconnect the spark plug leads, pull on the
extensions and not on the leads.
110421
109729