charging RENAULT TWINGO 2009 2.G Engine And Peripherals Service Manual

12B-16
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting
C44, and K9K
12B
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 Battery: Removal - Re-
fitting) (80A, Battery).
1 - Turbocharger oil supply pipe
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 air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the exhaust gas recirculation solenoid valve (see
14A, Antipollution, Exhaust gas recirculation
solenoid valve: Removal - Refitting, page 14A-
10) .
2 - turbocharger oil return pipe
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
1 - Turbocharger oil supply pipe
aRemove the bolt (1) of the turbocharger oil supply
pipe from the turbocharger.
aUndo the nut (2) of the turbocharger oil supply pipe
on the cylinder head.
aRemove the nut of the turbocharger oil supply pipe
on the cylinder head.
aRemove the turbocharger oil supply pipe. Special tooling required
Mot. 1746Offset wrench for tightening
High Pressure pump pipes.
Tightening torquesm
nut of the oil supply pipe
on the cylinder head35 Nm
bolt of the turbocharger
oil supply pipe on the
turbocharger14 Nm
turbocharger oil return
pipe bolts12 N.m
127900
127898

12B-17
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting
C44, and K9K
12B
2 - Oil return pipe
aRemove the bolts (3) of the oil return pipe from the
turbocharger.
aIn the direction of the arrows, rotate the oil return
pipe of the turbocharger to facilitate its removal.
aRemove the turbocharger oil pipe from the cylinder
block.
REFITTING
I - REMOVAL PREPARATION OPERATION
aAlways replace:
-the turbocharger oil supply pipe,
-the flat seal of the oil return pip on the turbocharg-
er,
-the O-ring of the oil return pip on the turbocharger.
aLubricate the O-ring of the oil return pipe on the tur-
bocharger with engine oil.
II - REFITTING OPERATION FOR PART
CONCERNED
1 - Turbocharger oil supply pipe
aFit the turbocharger oil supply pipe.
aRefit:
-the turbocharger oil supply pipe nut on the cylinder
head,-the bolt of the turbocharger oil supply pipe onto the
turbocharger.
aTorque tighten:
-the nut of the oil supply pipe on the cylinder
head ( 35 Nm) using the (Mot. 1746),
-the bolt of the turbocharger oil supply pipe on
the turbocharger (14 Nm).
2 - turbocharger oil return pipe
aFit the oil return pipe on the cylinder block.
aRefit the turbocharger oil return pipe bolts.
aTorque tighten the turbocharger oil return pipe
bolts (12 N.m).
III - FINAL OPERATION.
1 - Turbocharger oil supply pipe
aRefit:
-the exhaust gas recirculation solenoid valve (see
14A, Antipollution, Exhaust gas recirculation
solenoid valve: Removal - Refitting, page 14A-
10) ,
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-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).
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
2 - turbocharger oil return pipe
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aRefit the engine cover.
127899

12B-18
TURBOCHARGING
Intercooler: Removal - Refitting
D4F, and 780 or 782 – K9K, and 718
12B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-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).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the intercooler bolts (1) .
aLoosen the clip on the intercooler air outlet pipe (2) .
aDisconnect the intercooler air outlet pipe.
aUnclip the turbocharger air outlet pipe (3) .
aDisconnect the turbocharger air outlet pipe.
aRemove:
-the intercooler,
-the air deflector clips,
-the air deflector,
-the metal mounting.
REFITTING
I - REFITTING PREPARATION OPERATION
aCheck that the intercooler is not full of oil. In this
case, clean it with cleaning agent and let it dry (see
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products).
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the metal mounting,
-the air deflector,
-the air deflector clips,
-the intercooler.
aConnect the turbocharger air outlet pipe.
aClip on the turbocharger air outlet pipe.
aConnect the intercooler air outlet pipe.
aTighten the clip on the intercooler outlet pipe.
aRefit the intercooler bolts.
III - FINAL OPERATION
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).
122830

13B-9
DIESEL INJECTION
Diesel injection: List and location of components
K9K, and 740
13B
121436
(11) Pre-postheating unit
120039
(12) Turbocharging pressure sensor
(13) Exhaust gas recirculation sole-
noid valve
(14) Coolant temper ature sensor
(15) Turbocharger upstream inlet air
temperature sensor
(16) Turbocharger downstream inlet
air temperature sensor
120326
(17) Cylinder position sensor
120327
(18) Engine speed and position sen-
sor

13B-12
DIESEL INJECTION
Diesel injection: List and location of components
K9K, and 718
13B
122830
(19) Intercooler
141219
(20) Turbocharging pressure sole-
noid valve

14A-16
ANTIPOLLUTION
Exhaust gas recirculation assembly: Removal - Refitting
K9K
14A
aPull the intercooler air inlet pipe clip (5) on the turbo-
charger side.
aDisconnect the intercooler air inlet pipe (6) at the tur-
bocharger end.
aRemove the intercooler air inlet pipe nut (7) at the
turbocharger end.
aMove aside the intercooler air inlet pipe (6) at the tur-
bocharger end.
aDisconnect the vacuum pipe (8) from the turbo-
charging pressure regulator.
aUnclip:
-the turbocharging pressure regulator vacuum pipe
at (9) ,
-the brake servo vacuum pipe at (10) .
aDisconnect the brake servo vacuum pipe (11) .
aLoosen the clamp (12) for the air-air intercooler air
outlet pipe at the damper valve end.
aDisconnect the intercooler air outlet pipe (14) at the
damper valve end.
aRemove the nut (13) from the intercooler air outlet
pipe.
aMove the intercooler air outlet pipe (14) to one side. K9K, and 718
141222
141213
141217

14A-18
ANTIPOLLUTION
Exhaust gas recirculation assembly: Removal - Refitting
K9K
14A
aRefit:
-new seals on the coolant circulation cover,
-the coolant circulation cover on the exhaust gas
cooler.
aTorque tighten the coolant circulation cover bolts
on the exhaust gas cooler (12 N.m).
aRemove the tool (Ms. 583) from the coolant inlet and
outlet hoses of the exhaust gas cooler.
III - FINAL OPERATION
aFit the intercooler air outlet pipe at the damper valve
end.
aConnect the intercooler air outlet pipe on the side of
the damper valve.
aTorque tighten the intercooler air outlet pipe clip
at the damper valve end (5.5 N.m).
aRefit the intercooler air outlet pipe nut on the lifting
eye.
aConnect the turbocharging pressure regulator vacu-
um pipe.
aClip:
-the turbocharging pressure regulator vacuum pipe,
-the vacuum pipe from the brake servo.
aConnect the brake servo vacuum pipe.
aFit the intercooler air inlet pipe at the turbocharger
end.
aRefit the intercooler air inlet pipe nut at the turbo-
charger end on the lifting eye.
aConnect the intercooler air inlet pipe at the turbo-
charger end.
aClip on the intercooler air inlet pipe clip at the turbo-
charger end.
aRefit the air outlet pipe onto the air filter unit.
aTighten the air filter unit air outlet pipe clip on the tur-
bocharger.
aConnect the oil vapour rebreathing pipe.
aRefit:
-the exhaust gas recirculation rigid pipe (see 14A,
Antipollution, Exhaust gas recirculation rigid
pipe: Removal - Refitting, page 14A-19) ,-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the EGR solenoid valve (see 14A, Antipollution,
Exhaust gas recirculation solenoid valve: Re-
moval - Refitting, page 14A-10) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-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),
aConnect the battery (see ) (80A, Battery).
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) .
aRefit the engine cover. K9K, and 718

16A-1
STARTING - CHARGING
Alternator: Removal - Refitting
D4F or D7F, and STANDARD HEATING
16A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see ) (MR 411, 80A, Bat-
tery).
aRemove:
-the front right-hand wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres),
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection).
aUndo the lower bolt on the sub-frame tie-rod.
aRemove the upper bolt from the sub-frame tie-rod.
aRemove the sub-frame tie-rod.
aRemove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re-
fitting, page 11A-3) . Tightening torquesm
alter nator bolts25 Nm
sub-frame tie-rod lower
bolt62 Nm
sub-frame tie-rod upper
bolt21 Nm

16A-2
STARTING - CHARGING
Alternator: Removal - Refitting
D4F or D7F, and STANDARD HEATING
16A
aRemove:
-the filler neck bolt (1) ,
-the filler neck in the direction of the arrow (2) ,
-the dipstick.
aDisconnect the fuel pipe (3) from the injector rail.II - REMOVAL OPERATION FOR PART
CONCERNED
aDisconnect the connector (4) from the alternator wir-
ing harness.
aRemove:
-the alternator wiring harness nut (5) ,
-the alternator bolts,
-the alternator.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aClean the alternator pulley V-grooves to remove any
deposits. D4F, and 780
122392
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.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear latex gloves during the operation.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
109727

16A-3
STARTING - CHARGING
Alternator: Removal - Refitting
D4F or D7F, and STANDARD HEATING
16A
aPress in the rings (6) using pliers or a vice to make
the fitting operation easier.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the alternator,
-the alternator bolts.
aTorque tighten the alternator bolts (25 Nm).
aRefit:
-the power lead on the alternator,
-the power lead nut on the alternator.
aConnect the alternator excitation lead connector.
III - FINAL OPERATION
aConnect the fuel pipe to the injector rail.
aRefit:
-the dipstick,
-the filler neck,
-the filler neck bolt.
aAlways replace the accessories belt.aRefit the new accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re-
fitting, page 11A-3) .
aFit the sub-frame tie-rod.
aRefit the upper bolt on the sub-frame tie-rod.
aTorque tighten:
-the sub-frame tie-rod lower bolt (62 Nm),
-the sub-frame tie-rod upper bolt (21 Nm).
aRefit:
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres).
aConnect the battery (see ) (MR 411, 80A, Battery).
18987
D4F, and 780