timing RENAULT TWINGO 2009 2.G Engine And Peripherals Workshop Manual

13B-19
DIESEL INJECTION
High pressure pump: Removal - Refitting
K9K
13B
aRemove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re-
fitting, page 11A-3)
aUnclip the upper timing cover at (11) .
aRemove the upper timing cover.
aUnclip the lower timing cover at (12) .
aRemove:
-the plastic bolt (13) on the lower timing cover,-the lower timing cover.
K9K, and 740
19654
19654-1

13B-23
DIESEL INJECTION
High pressure pump: Removal - Refitting
K9K
13B
REFITTING
I - REFITTING PREPARATION OPERATION
a
aparts always to be replaced: Injection pump
sprocket nut
aparts always to be replaced: Front sub-frame
bolt
II - REFITTING OPERATION FOR PART
CONCERNED
aCheck that there is an indexing pin on the high pres-
sure pump shaft.
aPosition the high pressure pump on the cylinder
head whilst inserting it in its pulley.aFit the air filter unit bracket.
aFit the high pressure pump bolts on the cylinder
head, without tightening them, until contact is made.
aTighten to torque and in order the high pressure
pump bolts on the cylinder head (23 N.m).
aRefit the high pressure pump pulley, holding the high
pressure pump pulley with a 32 mm spanner.
aTorque tighten the high pressure pump pulley nut
(70 N.m) while holding the high pressure pump pul-
ley using a 32 mm spanner.
aCheck that the timing belt is correctly positioned and
in good condition.
aRemove the (Mot. 1606) from the cylinder head.
III - FINAL OPERATION
aRefit the suspended mounting on the cylinder head.
aTorque tighten the cylinder head suspended
mounting bolts (25 N.m). WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.
Note:
Check that the high pressure pump shaft is cor-
rectly orientated in relation to the pulley.
102085

13B-24
DIESEL INJECTION
High pressure pump: Removal - Refitting
K9K
13B
aRefit the lower timing cover.
aRefit the accessories belt (see 11A, Top and front
of engine, Accessories belt: Removal - Refitting,
page 11A-3)
aRefit:
-the upper timing cover,
-the camshaft position sensor (see 13B, Diesel in-
jection, Camshaft position sensor: Removal -
Refitting, page 13B-14) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) .
aRemove the blanking plugs.
aRefit a high pressure pipe between the pump and
the rail (see 13B, Diesel injection, High pressure
pipe between pump and rail: Removal - Refitting,
page 13B-35) .
aConnect the diesel return pipe to the venturi fitted to
the high pressure pump.aRefit:
-the fuel filter mounting,
-the fuel filter (see 13A, Fuel supply, Fuel filter:
Removal - Refitting, page 13A-4) .
aRefit:
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) ,
-the engine harness channel.
aFit the engine wiring on the engine wiring channel.
aClip on the engine wiring channel.
aConnect to the high pressure pump:
-the diesel supply pipe,
-the diesel return pipe to the diesel filter.
aClip on the high pressure pump pipes.
aRemove the protection on the alternator to prevent
fuel flowing out.
aConnect the connectors of:
-the diesel temperature sensor,
-the flow actuator,
-the injectors,
-the heater plugs.
aRemove the blanking cover which protects the oil
level dipstick guide inlet opening on the cylinder
block.
aRefit:
-the dipstick guide,
-the dipstick,
-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).
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 ) (80A, Battery). K9K, and 740
19659
Note:
Make sure that the tab (23) is positioned oppo-
site the mark (24) .

14A-12
ANTIPOLLUTION
Exhaust gas cooler: Removal - Refitting
K9K
14A
aUsing the workbench, remove:
-the cooler bolts (2) on its mounting (timing end),
-the mounting on the timing end,
-the mounting seal on the timing end,
-the cooler bolts on its mounting (gearbox side),
-the mounting (3) on the gearbox side,
-the mounting seal on the gearbox side.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: exhaust gas cooler
seal
aparts always to be replaced: Exhaust gas cooler
cover seal
aparts always to be replaced: Exhaust gas recir-
culation pipe seal
aparts always to be replaced: Exhaust gas recir-
culation rigid pipe
aUse an ABRASIVE PAD (see Vehicle: Parts and
consumables for the repair) (04B, Consumables -
Products) to clean the bearing faces:
-the intercooler and its mountings,
-the coolant circulation cover within the exhaust gas
cooler.
aUse CLEAN CLOTHS and SURFACE CLEANER
(see Vehicle: Parts and consumables for the re-
pair) (04B, Consumables - Products) to degrease
the bearing faces. K9K, and 740
121638
121640
K9K, and 718
WARNING
Ensure that the seals between the cooler and its
two supports are correctly positioned to avoid
any coolant leaks.

14A-13
ANTIPOLLUTION
Exhaust gas cooler: Removal - Refitting
K9K
14A
II - REFITTING OPERATION FOR PART
CONCERNED
aOn the workbench, refit the following to the intercoo-
ler:
-a new mounting seal on the gearbox side,
-the mounting on the gearbox side,
-the mounting bolts (gearbox side) onto the inter-
cooler without tightening them,
-a new exhaust gas recirculation rigid pipe,
-the bolts of the exhaust gas recirculation rigid pipe
bracket on the cooler without tightening them.
aFit the exhaust gas recirculation assembly onto the
cylinder head.
aAdjust the mounting (gearbox side) and the exhaust
gas recirculation rigid pipe until they are flat against
the cylinder head.
aFit the exhaust gas recirculation unit assembly bolts,
without tightening them.
aTighten the bolts of the mounting (gearbox side) and
of the exhaust gas recirculation rigid pipe on the ex-
haust gas cooler to secure them on the exhaust gas
cooler.
aRemove the exhaust gas recirculation assembly.
aOn the workbench, torque tighten:
-the mounting bolts (gearbox side) on the cooler
(12 N.m),
-the bolts of the exhaust gas recirculation rigid
pipe on the exhaust gas cooler (12 N.m),
-the bolts of the exhaust gas recirculation rigid
pipe bracket (25 N.m).aOn the workbench, refit the following to the intercoo-
ler:
-a new mounting seal on the gearbox side,
-the mounting on the gearbox side,
-the mounting bolts (gearbox side) onto the inter-
cooler without tightening them,
-a new mounting seal on the timing end,
-the mounting on the timing end,
-the mounting bolts (timing end) onto the intercooler
without tightening them.
aFit the exhaust gas recirculation assembly onto the
cylinder head.
aAdjust the two mountings until they are flat against
the cylinder head.
aFit the exhaust gas recirculation unit assembly bolts,
without tightening them.
aTighten the bolts of the two mountings on the ex-
haust gas cooler to immobilise them on the exhaust
gas cooler.
aRemove the exhaust gas recirculation assembly.
aOn the workbench, torque tighten the mounting
bolts on the cooler (12 N.m).
III - FINAL OPERATION
aRefit the exhaust gas recirculation assembly (see
14A, Antipollution, Exhaust gas recirculation as-
sembly: Removal - Refitting, page 14A-15) . K9K, and 718
Note:
The cooler must absolutely be able to move in
relation to the mounting (gearbox side) and to the
exhaust gas recirculation rigid pipe so that it can
be properly adjusted afterwards on the cylinder
head.
K9K, and 740
Note:
The cooler must absolutely be able to move in
relation to its tw o mountings so that it can be
properly adjusted afterwards on the cylinder
head.

19A-24
COOLING
Coolant pump: Removal - Refitting
D4F or D7F
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
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 wheel arch liner (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-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 rigid coolant pipe bolt on the multifunc-
tion support.
aMove the rigid water pump pipe aside.aRemove the coolant pump inlet pipe (see 19A,
Cooling, Coolant pump inlet pipe: Removal - Re-
fitting, page 19A-58) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the coolant pump bolts,
-the coolant pump,
-the coolant pump seal.
aRemove the coolant pump bolts.
aMove the coolant pump 5 mm away from its bearing
face.
aPivot the coolant pump casing in the direction of the
arrows, (1) and then (2) .
aRemove:
-the coolant pump, Tightening torquesm
coolant pump bolts10 N.m
AIR CONDITIONING
D4F, and 780 or 782
STANDARD HEATING
AIR CONDITIONING
120515

19A-25
COOLING
Coolant pump: Removal - Refitting
D4F or D7F
19A
-the coolant pump seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aApply SUPER CLEANER FOR JOINT FACES (see
Vehicle: Parts and consumables for the repair)
(MR 411, 04B, Consumables - Products) to the ar-
eas to be cleaned.
aLeave for approximately ten minutes.
aRemove the residue using a wooden spatula.
aComplete the cleaning of the parts using an abrasive
pad.
aDegrease the joint faces with SURFACE CLEANER
(see Vehicle: Parts and consumables for the re-
pair) (MR 411, 04B, Consumables - Products).
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the water pump fitted with a new seal,
-the coolant pump bolts.aTighten to torque and in order the coolant pump
bolts (10 N.m).
aRefit the coolant pump inlet pipe (see 19A, Cooling,
Coolant pump inlet pipe: Removal - Refitting,
page 19A-58) .
III - FINAL OPERATION
aFit the rigid water pump pipe with a new seal.
aRefit the rigid coolant pipe bolt on the multifunction
support.
aRefit:
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) , WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.
IMPORTANT
Wear latex gloves during the operation.
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).
120516
D4F, and 780 or 782
AIR CONDITIONING

19A-27
COOLING
Coolant pump: Removal - Refitting
K9K
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (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 right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-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 lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,
-the camshaft position sensor (see 13B, Diesel in-
jection, Camshaft position sensor: Removal -
Refitting, page 13B-14) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) .
aRemove:
-the inner timing cover bolts (1) ,
-the inner timing cover.
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) . Tightening torquesm
coolant pump bolts10 N.m
WARNING
The coolant helps to keep the engine running prop-
erly (heat exchange).
The system does not operate using pure water.
WARNING
Drain with the engine warm.
Flush and refill with the engine cold or warm.
Never flush a hot engine (risk of major thermal
shock).
102266

19A-29
COOLING
Coolant pump: Removal - Refitting
K9K
19A
aTighten to torque and in order the coolant pump
bolts (10 N.m).
III - FINAL OPERATION
aRefit:
-the inner timing cover,
-the inner timing cover bolts,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,
-the camshaft position sensor (see 13B, Diesel in-
jection, Camshaft position sensor: Removal -
Refitting, page 13B-14) ,
-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 right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper
front structure),-the halogen headlights (see Halogen headlight:
Removal - Refitting) (80B, Headlights),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-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),
-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).
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) .
102262

19A-30
COOLING
Coolant pump: Removal - Refitting
K4M
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).aRemove:
-the engine undertray,
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the headlights (see Halogen headlight: Removal
- Refitting) (80B, Headlights),
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
-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 air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-20) ,
-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 right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,
-the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-135) . Tightening torquesm
bolt 1 of the coolant
pump27 N.m
bolts 2 to 8 of the water
pump10 N.m
IMPORTANT
When working in the engine compartment, take
care as the radiator fan(s) may start up unexpect-
edly (risk of being cut).
To avoid any risk of serious burns when the engine
is hot:
-do not open the expansion bottle cap,
-do not drain the cooling system,
-do not open the bleed screw(s).
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
WARNING
When carr ying out a repair that requires a complete
change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
drive out the water, fill and bleed the circuit and
then measure the effective protection.
The cr iteria to be met are:
-protection down to -25˚C ±± ± ±
2 for cold and temper-
ate countries,
-protection down to -40˚C ±± ± ±
2 for "extreme cold"
countries.