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

13B-46
DIESEL INJECTION
Injector rail: Removal - Refitting
K9K
13B
aClean the high pressure pipe unions (13) between
the injection rail and the injectors (see 13B, Diesel
injection, Diesel injection: Precautions for the
repair, page 13B-1)
aRemove then dispose of:
-the clips between the high pressure pipes,
-the high pressure pipes between the rail and the in-
jectors.
aInsert the blanking plugs.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the nuts (14) from the injector rail,
-the injector rail.
REFITTING
I - REFITTING PREPARATION OPERATION
a
aAlways replace:
-the high pressure pipe between the pump and the
rail,
-the high pressure pipes between the rail and the in-
jector
aIn the event of replacement, torque tighten the
studs of the injection rail on the cylinder head (8
Nm ).
II - REFITTING OPERATION FOR PART
CONCERNED
aTake the injector rail out of its packaging.
121418
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
127901
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.

13B-47
DIESEL INJECTION
Injector rail: Removal - Refitting
K9K
13B
aRemove the blanking plugs.
aFit the injector rail.
aFit the injector rail nuts without tightening them.
III - FINAL OPERATION.
a
aRemove the blanking plugs from the high pressure
pump and the injection rail and discard them.
aFit the high pressure pipe between the high pressure
pump and the injection rail.
aTighten the high pressure pipe unions between the
pump and the rail until contact is made.
aRemove the blanking plugs on the injection rail and
the diesel fuel injectors then discard them.
aFit the new high-pressure pipes between the rail and
the injectors.
aTighten until contact the unions of the high pressure
pipes between the rail and injector.aFit and lock the new clips between the high pressure
pipes on the rail and injectors.
aTighten to torque:
-the injector rail nuts (28 Nm),
-the unions for the high pressure pipes between
the rail and the yellow-coloured injector (24
Nm) using the tool (Mot. 1746),
-the unions for the high pressure pipes between
the rail and the silver-coloured injector (28 Nm)
using the tool (Mot. 1746),
-the unions for the high pressure pipes between
the pump and the yellow-coloured rail (24 Nm)
using the tool (Mot. 1746),
-the unions for the high pressure pipes between
the pump and the silver-coloured rail (28 Nm)
using the tool (Mot. 1746),
aConnect to the high pressure pump:
-the fuel return pipe to the fuel filter,
-the fuel supply pipe.
aRefit the neck on the injection rail.
aRemove the protection fitted on the inlet opening of
the oil level dipstick on the cylinder block.
aRefit:
-the dipstick guide,
-the oil level dipstick nut,
-the oil level dipstick.
aConnect the injector rail pressure sensor connector.
aPosition the wiring harness in its channel.
aFasten the electrical wiring to the channel.
aConnect:
-the diesel temperature sensor,
-the fuel flow actuator,
-the injector connectors,
-the heater plug connectors.
aPrime the fuel circuit using a manual priming pump
until the disconnected pipes are filled with fuel.
aCheck that there are no fuel leaks.
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aCheck the high pressure circuit (see 13B, Diesel in-
jection, High pressure pipe: Check, page 13B-34)
.
aRefit the engine cover.
20960
WARNING
Before fitting a new high-pressure pipe, lightly
lubricate the nut threads with the oil from the
applicator provided in the new parts kit.
Be careful not to allow oil into the high-pressure
pipe.
Do not lubricate high-pressure pipes supplied
without an applicator, as these high-pressure
pipes are self-lubricating.

13B-49
DIESEL INJECTION
Fuel temperature sensor: Removal - Refitting
C44, and K9K
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the front engine cover.
aDisconnect the battery ( (see Battery: Removal -
Refitting) ).
aProtect the alternator from fuel outflow.
aDisconnect:
-the heater plug connectors (1) from cylinders 3 and
4,
-the injector connectors (2) from cylinders 3 and 4.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the fuel temperature sensor connector.
aRemove the fuel temperature sensor (3) from the
high pressure pump.
aMake sure that no impurities enter the high pressure
pump when the fuel sensor is removed.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit the fuel temperature sensor onto the high pres-
sure pump. Equipment required
Diagnostic tool
Tightening torquesm
fuel temperature sensor15 Nm
121418
102317
Note:
Prepare for the outflow of fuel.
WARNING
Do not blast with compressed air once the fuel
circuit is open, otherwise impurities may enter
the system. Only use cleaning cloths.
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-50
DIESEL INJECTION
Fuel temperature sensor: Removal - Refitting
C44, and K9K
13B
aTorque tighten the fuel temperature sensor (15
Nm).
aConnect the fuel temperature sensor connector.
II - FINAL OPERATION.
aConnect:
-the injector connectors for cylinders 3 and 4,
-the heater plug connectors for cylinders 3 and 4.
aRemove the protection on the alternator to prevent
fuel flowing out.
aConnect the battery ( (see Battery: Removal - Re-
fitting) ).
aStart the engine and check that there are no leaks.
aRefit the engine cover.
aUse the Diagnostic tool to check for an absence of
stored faults; deal with these and clear them as nec-
essary.

13B-53
DIESEL INJECTION
Accelerometer: Removal - Refitting
K9K
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the front engine cover.
aRemove:
-the dipstick,
-the oil level dipstick nut (1) ,
-the oil level dipstick guide.
aPlug the oil level dipstick guide inlet opening on the
cylinder block.
aDisconnect the following connectors :
-the heater plugs,
-the injectors,
-the flow actuator,-the diesel temperature sensor.
aDetach the channel at (2) .
aMove the wiring away from the channel.
aRemove:
-the nut (3) from the channel,
-the neck. Special tooling required
Emb. 1797Socket (24 mm) for removal -
refitting of the clutch master
cylinder
Equipment required
Diagnostic tool
Tightening torquesm
accelerometer20 N.m
114527
121419

13B-54
DIESEL INJECTION
Accelerometer: Removal - Refitting
K9K
13B
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the accelerometer connector (4) .
aRemove the accelerometer (4) using the (Emb.
1797).
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit the accelerometer.
aTorque tighten the accelerometer (20 N.m) using
the (Emb. 1797).
aConnect the accelerometer connector.
II - FINAL OPERATION
aRefit:
-the channel,
-the channel nut.
aPosition the channel wiring harness.
aClip on the channel.
aConnect the connectors of:
-the heater plugs,
-the injectors,
-the flow actuator,
-the diesel temperature sensor.aRemove the blanking cover which protects the oil
level dipstick guide inlet opening on the cylinder
block.
aRefit:
-the dipstick guide,
-the oil level dipstick nut,
-the dipstick.
aRefit the channel nuts.
aRefit the engine cover.
109939
Note:
When replacing the accelerometer, run the
appropriate command (see Fault finding repair
manual) using the Diagnostic tool in order to
carr y out the necessary programming.

13C-2
PREHEATING
Heater plugs: Removal - Refitting
K9K
13C
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the front engine cover.
aUnclip the fuel supply pipes (1) from the right-hand
suspended engine mounting.
aMove the fuel supply pipes away from the right-hand
suspended engine mounting.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the heater plug connectors (2) .
aClean the edges of the heater plugs using a com-
pressed air nozzle to avoid any impurities getting
into the cylinders. Equipment required
compressed air nozzle
hinged wrench for heater plug
Tightening torquesm
heater plugs15 Nm
120045
127895
IMPORTANT
Wear goggles with side protectors for this opera-
tion.

13C-3
PREHEATING
Heater plugs: Removal - Refitting
K9K
13C
a
aLoosen the heater plugs (3) using a 10 mm long ra-
dio socket connected to a universal joint or a hinged
wrench for heater plug.
aUse a hose to unscrew the heater plugscompletely.
aRemove the heater plugs.
aBlock the plug wells on the cylinder head using clean
cloths throughout the removal operation.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRemove the protection on the openings of the plug
well(s) on the cylinder head.
aBolt without tightening the heater plugs using the
hose.
aTorque tighten the heater plugs (15 Nm).
aConnect the heater plug connectors.
II - FINAL OPERATION.
aFit the fuel pipes on the right-hand suspended en-
gine mounting.aClip the fuel supply pipes onto the right-hand sus-
pended engine mounting.
aRefit the engine cover.
127905
Note:
If the heater plugs jam, use the heater plug
removal tool (see ) (Technical Note 5197A, 06A,
Tools).

14A-10
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting
K9K
14A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aConsumables (see Vehicle: Parts and consuma-
bles for the repair) (02A, Parts and consumables):
-ABRASIVE PAD,
-SURFACE CLEANER.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the engine cover,
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the bolts (1) from the exhaust gas recirculation so-
lenoid valve,
-the exhaust gas recirculation solenoid valve,
-the exhaust gas recirculation solenoid valve seal.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aUsing the ABRASIVE PADS, clean the joint faces of
the exhaust gas recirculation solenoid valve.
aAfterwards, degrease these bearing faces using
SURFACE CLEANER and clean cloths.
aRefit a new seal on the exhaust gas recirculation so-
lenoid valve.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the exhaust gas recirculation solenoid valve with its
new seal,
-the bolts to the exhaust gas recirculation solenoid
valve.
aTorque tighten the exhaust gas recirculation sole-
noid valve bolts (10 Nm).
III - FINAL OPERATION.
aRefit:
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the engine cover.
aIf the EGR solenoid valve is being replaced, carry
out the necessary programming (see MR 413 Fault
finding, 13B, Fault finding - Replacement of com-
ponents, Operation for replacing the EGR sole-
noid valve). Tightening torquesm
exhaust gas recircula-
tion solenoid valve bolts10 Nm
121637

14A-11
ANTIPOLLUTION
Exhaust gas cooler: Removal - Refitting
K9K
14A
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 ) (80A, Battery).
aRemove:
-the engine cover,
-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 unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the EGR solenoid valve (see 14A, Antipollution,
Exhaust gas recirculation solenoid valve: Re-
moval - Refitting, page 14A-10) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,-the exhaust gas recirculation rigid pipe (see 14A,
Antipollution, Exhaust gas recirculation rigid
pipe: Removal - Refitting, page 14A-19) ,
-the exhaust gas recirculation assembly (see 14A,
Antipollution, Exhaust gas recirculation as-
sembly: Removal - Refitting, page 14A-15) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUsing the workbench, remove:
-the cooler bolts (1) on its mounting (gearbox side),
-the mounting on the gearbox side,
-the mounting seal on the gearbox side. Tightening torquesm
mounting bolts (gear-
box side) on the cooler12 N.m
bolts of the exhaust gas
recirculation rigid pipe
on the exhaust gas
cooler12 N.m
bolts of the exhaust gas
recirculation rigid pipe
bracket25 N.m
mounting bolts on the
cooler12 N.m
exhaust gas recircula-
tion r igid pipe bolts36 N.m
K9K, and 718
141215
141216