RENAULT TWINGO 2009 2.G Engine And Peripherals Workshop Manual

13B-30
DIESEL INJECTION
Flow actuator: Removal - Refitting
K9K
13B
aFit the high pressure pump pipes.
aConnect to the high pressure pump:
-the diesel fuel supply pipe,
-the diesel return pipe.
aAttach the high pressure pump pipes.
aRemove the protection on the alternator to prevent
fuel flowing out.
aConnect the connectors:
-the heater plugs,
-the injectors,
-the flow actuator,
-diesel fuel temperature sensor.
aRemove the blanking cover protecting the dipstick
guide inlet orifice on the cylinder block.
aRefit:
-the dipstick guide,
-the dipstick guide nut,
-the oil level dipstick.
aRefit the neck nuts.
aPrime the fuel circuit with a manual priming pump
until the disconnected pipes are filled with fuel; if
necessary, bleed the fuel filter (see 13A, Fuel sup-
ply, Fuel filter: Removal - Refitting, page 13A-4) .
aConnect the battery (see ) (MR 411, 80A, Battery).
aCheck that there are no fuel leaks.
aCheck the high pressure circuit (see 13B, Diesel in-
jection, High pressure pipe: Check, page 13B-34)
.
aUse the Diagnostic tool to check for an absence of
stored faults; deal with these and clear them as nec-
essary.
aRefit the engine cover.

13B-31
DIESEL INJECTION
Venturi: Removal - Refitting
K9K
13B
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aConsumable:
-cleaning cloths (Part no. 77 11 211 707).
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the front engine cover.
aProtect the alternator from fuel outflow.aDisconnect the diesel return pipe from the high pres-
sure pump (1) .
aInsert the blanking plugs.
aUnclip the diesel return pipe on the neck then re-
move it from the high pressure pump. Tightening torquesm
venturi bolt on the high
pressure pump5.5 Nm
Note:
Observe the repair precautions (see 13B, Die-
sel injection, Diesel injection: Precautions for
the repair, page 13B-1) .
Make sure that you have a new venturi before
opening the fuel circuit.
120045
Note:
Be prepared for the outflow of diesel.
WARNING
Keep the pipe unions away from contaminated
areas.

13B-32
DIESEL INJECTION
Venturi: Removal - Refitting
K9K
13B
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the diesel return pipe (2) on the venturi.
aFit anti-contamination caps.
aRemove the high pressure pump venturi bolt (3) .
aRemove the venturi (by hand with small tugs and
successive turns).
aMake sure that no impurities enter the high pressure
pump when the venturi is removed.REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a
aRefit the venturi to the high pressure pump.
aRefit the venturi bolt to the high pressure pump.
aTorque tighten the venturi bolt on the high pres-
sure pump (5.5 Nm).
aRemove the blanking plugs.
aConnect the diesel return pipe to the venturi.
II - FINAL OPERATION.
aClip the high pressure pump diesel return pipe onto
the neck.
aRemove the blanking plugs.
aConnect the diesel return pipe to the high pressure
pump.
aAttach the diesel return pipe to the neck.
aRemove the protection on the alternator to prevent
fuel flowing out.
102316
Note:
Make preparations for fuel outfl ow.
Note:
Make preparations for fuel outfl ow.
WARNING
Do not blast with compressed air once the fuel
circuit is open, otherwise impurities may enter
the system. Only use cleaning cloths.
WARNING
Do not remove the components from their pack-
aging until just before fitting them to the vehicle.
Note:
Do not lubricate the seals with grease or old die-
sel fuel. Use the applicator provided in the kit for
the new par t.

13B-33
DIESEL INJECTION
Venturi: Removal - Refitting
K9K
13B
aPrime the fuel circuit using the manual priming pump
(4) until the disconnected pipes are filled with fuel
(automatic degassing).
aCheck that there are no fuel leaks.
aStart the engine.
aCheck that there are no fuel leaks.
aRefit the engine cover.
120045

13B-34
DIESEL INJECTION
High pressure pipe: Check
K9K
13B
a
CHECK
aRemove the front engine cover.
aPrime the fuel circuit with the manual priming pump
until the disconnected pipes are filled with fuel (auto-
matic degassing).
aCheck that there are no fuel leaks.
aConnect the Diagnostic tool to the vehicle.aDeal with present faults,
aActivate command AC029 “high pressure circuit
sealing test”.
aCheck that there are no fuel leaks.
aDeal with the causes of any possible leaks.
aUse the Diagnostic tool to check for stored faults;
deal with these and clear them as necessary.
aDisconnect the Diagnostic tool.
aRefit the engine cover. Equipment required
Diagnostic tool
Note:
Check that there are no diesel leaks after each
operation.
Note:
The Diagnostic tool can be used to test the high
pressure circuit with the engine running. This
command can be used to run fault finding on a
leak due to an incorrectly fitted or tightened
union. This command only works if the engine
coolant temperature is greater than 60˚. The fault
finding procedure will not reveal small leaks due
to incorrect tightening.
IMPORTANT
Consult the safety and cleanliness advice and
operation recommendations before carrying out
any repair (see 13B, Diesel injection, Diesel
injection: Precautions for the repair, page
13B-1) .Note:
Certain faults will prevent this test from being
carr ied out: deal with them first.
Note:
The engine automatically runs a cycle of four
acceler ations and decelerations to lower the rail
pressure.
Note:
Do not leave anything on the engine compart-
ment dur ing the test phase (significant vibration).

13B-35
DIESEL INJECTION
High pressure pipe between pump and rail: Removal - Refitting
K9K
13B
PARTS AND CONSUMABLES FOR THE REPAIR
Pièces à remplacer systématiquement :
-the high pressure pipe between the pump and the rail.
Ingrédients :
-cleaning cloths,
-set of K9K blanking plugs (injection DELPHI).
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see ) (MR 411, 80A, Bat-
tery).
aRemove the front engine cover.aRemove:
-the dipstick,
-the dipstick guide nut (1) ,
-the oil level dipstick guide.
aBlock the dipstick guide inlet opening on the cylinder
block.
aDisconnect the connectors:
-the heater plugs,
-the injectors,
-the flow actuator,
-diesel fuel temperature sensor.
aProtect the alternator and the starter from fuel out-
flow. Special tooling required
Mot. 1746Offset wrench for tightening
High Pressure pump pipes.
Equipment required
Diagnostic tool
Tightening torquesm
high pressure pipe
unions between the
pump and the yellow rail24 Nm
high pressure pipe
unions between the
pump and the silver rail28 Nm
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 13B, Diesel injection, Diesel injec-
tion: Precautions for the repair, page 13B-1) .
114527

13B-36
DIESEL INJECTION
High pressure pipe between pump and rail: Removal - Refitting
K9K
13B
aClean the diesel pipe unions on the high pressure
pump (see 13B, Diesel injection, Diesel injection:
Precautions for the repair, page 13B-1) .
aDisconnect the high pressure pump from:
-the diesel supply pipe (2) ,
-the diesel return pipe (3) to the diesel filter.
aFit suitable blanking plugs on:
-the high pressure pump,
-the high-pressure pipes.aUnclip the neck at (4) .
aRemove the neck wiring harness.
aRemove:
-the neck nut (5) ,
-the neck.
121423
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.121419

13B-37
DIESEL INJECTION
High pressure pipe between pump and rail: Removal - Refitting
K9K
13B
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aClean the high pressure pipe unions (6) between the
pump and the rail (see 13B, Diesel injection, Die-
sel injection: Precautions for the repair, page
13B-1) .
aRemove the high pressure pipe (6) between the
pump and the rail and discard it.
aFit suitable blanking plugs on:
-the high pressure pump,
-the injector rail.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aII - REFITTING OPERATION FOR PART
CONCERNED
a
aFit a new high pressure pipe between the pump and
the rail.
aScrew on the high pressure pipe unions between the
pump and the rail without tightening them until con-
tact is made.
aUsing the (Mot. 1746), tighten to torque:
-the high pressure pipe unions between the
pump and the yellow rail (24 Nm),
-the high pressure pipe unions between the
pump and the silver rail (28 Nm).
III - FINAL OPERATION.
aRefit:
-the channel,
-the neck nut.
aFit the neck wiring harness.
121419
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
WARNING
Only remove the blanking plugs from the pro-
tected components at the last possible moment.
Also, do not remove the components from their
packaging until just before fitting them to the
vehicle.
20960
WARNING
Before fitting a new high pressure pipe, lightly
lubricate the nut threads with oil from the applica-
tor provided in the new par t.
Be careful not to allow oil into the high pressure
pipe.
Do not lubricate high pressure pipes supplied
without an applicator; these pipes are self-lubri-
cating.

13B-38
DIESEL INJECTION
High pressure pipe between pump and rail: Removal - Refitting
K9K
13B
aClip the neck on.
aConnect to the high pressure pump:
-the diesel fuel supply pipe,
-the diesel return pipe to the diesel filter.
aRemove the protection on the alternator and starter.
aConnect the connectors:
-the heater plugs,
-the injectors,
-the flow actuator,
-diesel fuel temperature sensor.
aRemove the blanking cover protecting the dipstick
guide inlet orifice on the cylinder block.
aRefit:
-the dipstick guide,
-the dipstick guide nut,
-the dipstick,
-the neck nuts.
aPrime the fuel circuit with a manual priming pump
until the disconnected pipes are filled with fuel; if
necessary, bleed the fuel filter (see 13A, Fuel sup-
ply, Fuel filter: Removal - Refitting, page 13A-4) .
aCheck that there are no fuel leaks.
aConnect the battery (see ) (MR 411, 80A, Battery).
aCheck the high pressure circuit (see 13B, Diesel in-
jection, High pressure pipe: Check, page 13B-34)
.
aUse the Diagnostic tool to check for an absence of
stored faults; deal with these and clear them as nec-
essary.
aRefit the engine cover.

13B-39
DIESEL INJECTION
High pressure pipe between rail and injector: Removal - Refitting
K9K
13B
PARTS AND CONSUMABLES FOR THE REPAIR
Pièces à remplacer systématiquement :
-the high pressure pipes between the rail and the in-
jectors.
Ingrédients :
-cleaning cloths,
-set of K9K blanking plugs (injection DELPHI).
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see ) (MR 411, 80A, Bat-
tery).
aRemove the front engine cover.aRemove:
-the dipstick,
-the dipstick guide nut (1) ,
-the oil level dipstick guide.
aBlock the dipstick guide inlet opening on the cylinder
block.
aDisconnect the connectors:
-the heater plugs,
-the injectors,
-the flow actuator,
-diesel fuel temperature sensor.
aProtect the alternator and the starter from fuel out-
flow. Special tooling required
Mot. 1746Offset wrench for tightening
High Pressure pump pipes.
Equipment required
Diagnostic tool
Tightening torquesm
high pressure pipe
unions between the
pump and the yellow rail24 Nm
high pressure pipe
unions between the
pump and the silver rail28 Nm
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 13B, Diesel injection, Diesel injec-
tion: Precautions for the repair, page 13B-1) .
WARNING
Obtain the special high pressure injection circuit
blanking plugs kit.
Always replace any high pressure pipe or high pres-
sure pipe clip removed with a new one.
114527