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

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

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

13A-1
FUEL SUPPLY
Diesel supply circuit: Operating diagram
K9K
13A
The diesel fuel supply system includes a diesel injec-
tion computer and various sensors.
120417
(1) Fuel tank
(2) Dipstick
(3) Electrical diesel fuel reheater
(4) Man ual priming pump
(5) Diesel filter
(6) High pressure pump
(7) Fuel fl ow actuator
(8) Injector rail
(9) Injector rail pressure sensor
(10) Diesel injector
(11) Venturi
IMPORTANT
Loosening a high pressure pipe union when the
engine is running is strictly prohibited.
WARNING
It is forbidden:
-to dismantle the interior of the pump or injectors.
-to remove the pressure sensor from the fuel rail
(because of circuit contamination problems). If the
pressure sensor fails, the pressure sensor, the rail
and the five high pressure pipes must be replaced,
-to dismantle the flow regulator solenoid valve and
the pressure regulator solenoid valve on the high
pressure pump.

13A-2
FUEL SUPPLY
Manual priming pump: Removal - Refitting
K9K
13A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aCONSUMABLES:
-cleaning cloths.
a
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove the front engine cover.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDetach the fuel pipe from the body.
aDisconnect the electric diesel fuel heater fuel pipe
union (1) .
aUnclip the fuel pipe. 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.
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) .
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
120049
WARNING
To prevent impur ities from entering the circuit,
plugs must be fitted to the openings of all the fuel
circuit components exposed to the open air.
WARNING
Keep the pipe unions away from contaminated
areas.

13A-3
FUEL SUPPLY
Manual priming pump: Removal - Refitting
K9K
13A
aDisconnect the fuel pipe union (2) .
aRemove the manual priming pump.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a
aRefit the manual priming pump.
aConnect the fuel pipe union.
aClip on the fuel pipe.
aConnect the fuel pipe union to the electric diesel fuel
heater.
aClip the fuel pipe on to the body.
II - FINAL OPERATION.
aOpen the bleed screw on top of the fuel filter.
aPrime the fuel circuit using a manual priming pump
until the disconnected pipes are filled with fuel.
aClose the bleed screw on top of the fuel filter.aCheck that there are no fuel leaks.
aStart the engine.
aCheck that there are no fuel leaks.
aSwitch off the engine.
aRefit the engine cover.
120045
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.

13A-4
FUEL SUPPLY
Fuel filter: Removal - Refitting
K9K
13A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aCONSUMABLES:
-cleaning cloths.
aMake sure you have a new diesel filter before open-
ing the fuel circuit.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the front engine cover.aDisconnect the fuel filter:
-the high pressure pump inlet pipe (1) ,
-the manual priming pump outlet pipe (2) .
aRemove the fuel supply pipes (1) and (2) . 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.
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:
Periodically bleed the water contained in the die-
sel filter via the bleed screw (see maintenance
handbook for vehicle concerned).
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
121441
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
WARNING
To prevent impur ities from entering the circuit,
plugs must be fitted to the openings of all the fuel
circuit components exposed to the open air.
WARNING
Keep the pipe unions away from contaminated
areas.

13A-5
FUEL SUPPLY
Fuel filter: Removal - Refitting
K9K
13A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the fuel filter mounting nut (3) ,
-the fuel filter from its mounting.
aDetach the water detection sensor offset connector
on the fuel filter mounting (if fitted).
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aaAttach the water detection sensor offset connector
to the fuel filter mounting (if fitted).
aRefit the fuel filter to its mounting.
aFit the fuel filter mounting nut.
II - FINAL OPERATION.
aPosition the fuel pipes.
aConnect to the fuel filter:
-the manual priming pump outlet pipe,
-the high pressure pump inlet pipe.
aOpen the bleed screw on top of the fuel filter.
aPrime the fuel circuit using a manual priming pump
until the disconnected pipes are filled with fuel.
aClose the bleed screw on top of the fuel filter.
aCheck that there are no fuel leaks.
aStart the engine.
aCheck that there are no fuel leaks.
aSwitch off the engine.
aRefit the engine cover.
BLEEDING
aRemove the fuel filter mounting nut.
aDetach the manual priming pump.
aRemove the fuel filter without pulling on the water
detection sensor wiring harness in the diesel fuel.
aPosition a container under the fuel filter which has
been removed from its mounting.
aTurn the bleed cap or the water detection sensor in
the diesel fuel (depending on equipment) by no
more than one turn.
aAllow it to flow until diesel fuel appears.
aClose the bleed cap or the water detection sensor
(depending on equipment).
121441
Note:
If the fuel filter is to be reused, fit blanking plugs
to the fuel supply pipes and fuel filter openings,
using the appropriate blanking plug kit, depend-
ing on the engine (see 13B, Diesel injection,
Diesel injection: Precautions for the repair,
page 13B-1) .
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:
Chec k that the fuel filter is correctly positioned
and secure on its mounting by shaking it: the fil-
ter must not move.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.

13A-7
FUEL SUPPLY
Electric diesel fuel heater: Removal - Refitting
C44, and K9K
13A
REMOVAL
I - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the vehicle on a two-post lift ( (see Vehicle:
Towing and lifting) ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the electric diesel fuel heater electrical
connector (1) .
aRemove the nut (2) from the electric diesel fuel heat-
er mounting on the body.
aDisconnect the inlet and outlet fuel supply pipes (3)
from the electric diesel fuel heater.
aRemove the electric diesel fuel heater and its mount-
ing from the vehicle.
aSeparate the electric diesel fuel heater from its
mounting, letting it flow.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aFit then lock the electric diesel fuel heater to its
mounting.
aFit the electric diesel fuel heater and its mounting to
the vehicle.
aConnect the electric diesel fuel heater inlet and out-
let fuel supply pipes.
aRefit the electric diesel fuel heater mounting nut on
the body.
aTighten the diesel heater mounting nut on the body.
aConnect the electric diesel fuel heater electrical con-
nector.
aPrime the diesel circuit using the manual priming
pump (4) .
aStart the engine then let it run for a few minutes to
check that it starts properly and to check that there
are no leaks.
II - FINAL OPERATION.
aDeal with possible fuel leaks.
120049
Note:
Make preparations for fuel outfl ow.
120045