fuel pressure RENAULT TWINGO 2009 2.G Engine And Peripherals User Guide

11A-37
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting
D4F
11A
aCheck that the tensioning roller does not come into
contact with the cylinder head.
aIf the tensioning roller is in contact with the cylinder
head:
-set the engine to Top Dead Centre,
-remove the tensioning roller and the timing belt,
-insert the tensioning roller pin,
-repeat the timing belt refitting method from the be-
ginning, step by step.
III - FINAL OPERATION
aRefit:
-the lower timing cover,
-the lower timing cover bolt,
-the timing intermediate housing,
-the intermediate timing cover bolts,
-the upper timing cover,
-the upper timing cover.
aTorque tighten:
-the lower timing cover bolt (10 N.m),
-the intermediate timing cover bolts (10 N.m),
-the upper timing cover bolts (37 N.m)aFit the oil pressure sensor connector.
aClip the oil pressure sensor wiring on the upper tim-
ing cover.
aConnect the oil pressure sensor connector.
aFit the flexible heat shield on the oil pressure sensor
connector.
aClip the fuel pipe on to the upper timing cover.
aRefit:
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the rear suspended engine mounting (see 19D,
Engine mounting, Lower engine tie-bar: Re-
moval - Refitting, page 19D-18) .
aRemove the tool (Mot. 1379).
aRefit:
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-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).
aConnect the battery (see ) (80A, Battery).
109765
D4F, and 780 or 782

11A-114
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
K9K
11A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the front engine cover.
aDisconnect the battery (see ) (80A, Battery).
aRemove:
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (85A, Wiping -
Washing),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),-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),
-the halogen headlights (see Halogen headlight:
Removal - Refitting) (80B, Headlights),
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper
front structure),
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) .
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aRemove:
-the nut from the dipstick guide,
-the dipstick guide.
aDisconnect:
-the injector connectors,
-the heater plug connectors ,
-the connectors to the high pressure pump,
-injector rail pressure sensor connector,
-the accelerometer connector.
aRemove the nut from the engine wiring channel.
aMove aside the engine wiring.
aDisconnect the fuel inlet and return pipes from the
high pressure pump. Special tooling required
Mot. 1202-01Clip pliers for hose clips
(large size).
Mot. 1202-02Clip pliers for hose clips
(small size)
Mot. 1448Remote operation pliers for
hose clips .
Equipment required
cylinder head bolt tightening gauge (angular mea-
suring type)
Tightening torquesm
cylinder head bolts (ini-
tial torque)25 N.m
cylinder head bolts270˚ ±± ± ±
10˚
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to r un.
IMPORTANT
Dur ing this operation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting
the union.

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

11A-131
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
aRemove the bolts (2) on the intercooler outlet air
pipe.
aMove the intercooler outlet air pipe away from the
throttle valve.
aUndo the compressor discharge valve air pipe clip
(3) .
aDisconnect:
-the turbocharging solenoid valve connector to the
turbocharger,
-the compressor discharge valve air pipe from the
air filter unit outlet air pipe.aUnclip the injection wiring from the inlet manifold.
aDisconnect:
-the upstream oxygen sensor connector (4) .
-the air inlet pressure connector (5) ,
-the injector rail - injector wiring connector (6) ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the throttle body connector ,
-the coolant temperature sensor connector.
aDisconnect the petrol supply union on the injector
rail - injector.
aPlug the openings.
aMove aside the engine wiring.
122390121765
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to r un.
IMPORTANT
Dur ing this operation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting
the union.

11A-133
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
2 - Checking the gasket face
aCheck the flatness of the cylinder head gasket face
(see Cylinder head: Check) .
3 - Optional additional operations
aWhen replacing the cylinder head, strip the cylinder
head (see Cylinder head: Stripping - Rebuilding) .
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.
aCheck for the cylinder head centring dowels on the
cylinder block.
aFit a new cylinder head gasket onto the cylinder
block, positioning the marking (8) on the oil filter
side.
aRefit 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) (20 N.m).
aCheck that the cylinder head bolts are tightened to
20 N.m.
aAngle tighten in order the cylinder head bolts (230˚
±± ± ±
6˚).
III - FINAL OPERATION
aConnect the cooling hoses.
aRefit:
-the cooling hose clips using the (Mot. 1448),
-the engine wiring.
aRemove the blanking plugs.
aConnect:
-the petrol inlet union on the injector rail - injectors.
-the coolant temperature sensor connector,
-the throttle body connector ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the injector rail - injector wiring connector,
-the air inlet pressure connector.
-the upstream oxygen sensor connector.
aClip the injection wiring onto the inlet manifold.
aConnect:
-the compressor discharge valve air pipe to the air
filter unit outlet air pipe, WARNING
No regrinding of the cylinder head is permitted.
19598
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.
18641

12A-14
FUEL MIXTURE
Air filter unit: Removal - Refitting
K9K
12A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the front engine cover.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip:
-the air filter air inlet pipe (1) on the vehicle,
-the air filter air inlet pipe from the air filter unit.
aRemove the air filter air inlet pipe.aUnclip the air filter box harnesses.
aDisconnect the connectors:
-from the air inlet temperature sensor downstream
of the turbocharger (3) ,
-the turbocharger pressure sensor (4) ,
-from the air inlet temperature sensor upstream of
the turbocharger (5) ,
-from the EGR (6) .
aRemove the bolt (7) from the turbocharger pressure
sensor on the air filter box.
aMove aside the turbocharger pressure sensor.
aLoosen the clip at the inlet of the air filter outlet air
pipe.
aUnclip the air filter outlet air pipe from the air filter
box.
aRaise the cover of the air filter box to remove it from
its mountings.
aSlide the air filter box towards the timing end.
aRemove the air filter box.
120038
Note:
Make sure you do not break the pins (2) .
120039

12A-15
FUEL MIXTURE
Air filter unit: Removal - Refitting
K9K
12A
REMOVAL
I - REFITTING OPERATION FOR PART
CONCERNED
aSlide the air filter box towards the gearbox side.
aCheck the condition of the air filter box mountings,
replace them if necessary.
aClip:
-the air filter box onto its mountings,
-the air filter air outlet pipe to the air filter.
aTighten the air pipe clip on the air filter outlet.
aRefit the air filter air inlet pipe on the vehicle.
aPosition the turbocharger pressure sensor on the air
filter box.
aRefit the bolt mounting the turbocharger pressure
sensor on the air filter box.
aConnect the connectors:
-of the inlet air temperature sensor,
-of the turbocharging pressure sensor,
-of the flow sensor,
-of the EGR.
aClip on the air filter box harnesses.
aClip the air filter inlet air pipe to the air filter box.
II - FINAL OPERATION.
aRefit the engine cover.Note:
Ensure that the centring lug of the box is fully
inserted in the cylinder head.

12A-30
FUEL MIXTURE
Inlet distributor: Removal - Refitting
D7F
12A
aDisconnect the spark plug high voltage wiring har-
ness (2) .
aMove aside the spark plug high voltage wiring har-
ness.
aDisconnect:
-the petrol vapour rebreather pipe from the inlet dis-
tributor (3) ,
-the non-return valve pipe on the inlet distributor (4)
,
-the air inlet pressure sensor connector (5) ,
-the air temperature sensor connector (6) ,
-the injector connector (7) ,-the fuel supply pipe intermediate union (8) ,
-the oil vapour rebreathing pipe from the inlet dis-
tributor.
aRemove the dipstick.
aRemove:
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the alternator upper bolt.
aTilt the alternator forward.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the nuts from the air inlet distributor on the
cylinder head.
121737
IMPORTANT
During this operation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting
the union.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
IMPORTANT
Wear latex gloves during the operation.
AIR CONDITIONING
121734

12A-31
FUEL MIXTURE
Inlet distributor: Removal - Refitting
D7F
12A
aRemove:
-the air inlet distributor bolts on the rocker cover (9) ,
-the inlet distributor.
When replacing the inlet distributor
aRemove:
-the fuel supply pipe from the injector rail,
-the injector rail bolts,
-the injector rail.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the inlet distributor seals.
When replacing the inlet distributor
aRefit:
-the injector rail fuel supply pipe on the inlet distrib-
utor,
-the injector rail,
-the injector rail bolts.
aTorque tighten the injector rail bolts (7 N.m).
aRefit:
-the motorised throttle valve with a new seal,
-the motorised throttle valve bolts.
aTorque tighten the motorised throttle valve bolts
(10 N.m).II - REFITTING OPERATION FOR PART
CONCERNED
aFit the inlet distributor with new seals
aFit without tightening:
-the inlet distributor nuts on the cylinder head,
-the inlet distributor bolts on the rocker cover.
aPre-tighten to torque:
-the inlet distributor nuts on the cylinder head
(initial torque) (8 N.m),
-the inlet distributor bolts on the rocker cover
(initial torque) (3 N.m).
aTorque tighten:
-the inlet distributor nuts on the cylinder head
(17 N.m),
-the inlet distributor bolts on the rocker cover
(10 N.m).
III - FINAL OPERATION
aConnect:
-the oil vapour induction pipe from inlet distributor ,
-the fuel supply pipe intermediate union,
-the injector connectors,
-the air temperature sensor connector,
-the air inlet pressure sensor connector,
-the non-return valve pipe on the inlet distributor,
-the petrol vapour rebreather pipe.
121735