alternator RENAULT TWINGO 2009 2.G Engine And Peripherals Owner's Manual

13B-16
DIESEL INJECTION
High pressure pump: Removal - Refitting
K9K
13B
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).
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,
-of the injectors,
-the flow actuator,
-the diesel temperature sensor.
aProtect the alternator from fuel outflow. Special tooling required
Mot. 1672Low er engine support.
Mot. 1430Set of 5 crankshaft and cam-
shaft pulley timing pins.
Mot. 1606High pressure pump pulley
support tool.
Mot. 1525Gear extractor for tapered
hub injection pump.
Mot. 1525-02Adapter claws for Mot. 1525.
Equipment required
Diagnostic tool
Tightening torquesm
high pressure pump
bolts on the cylinder
head23 N.m
high pressure pump pul-
ley nut70 N.m
cylinder head sus-
pended mounting bolts25 N.m
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-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) .

13B-26
DIESEL INJECTION
Flow actuator: Removal - Refitting
K9K
13B
PIECES ET INGREDIENTS POUR LA REPARATION
Pièces à remplacer systématiquement :
-the high pressure pipe between the rail and injector
number 4,
-the clip between high pressure pipes number 3 and 4.
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 from fuel outflow. Special tooling required
Mot. 1746Offset wrench for tightening
High Pressure pump pipes.
Equipment required
Diagnostic tool
Tightening torquesm
fuel flow actuator bolts
on the high pressure
pump6 Nm
high pressure pipe
unions between the rail
and injector number 4
(yellow)24 Nm
high pressure pipe
unions between the rail
and injector number 4
(silver)28 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-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-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-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

13B-42
DIESEL INJECTION
High pressure pipe between rail and injector: Removal - Refitting
K9K
13B
aFit and lock a new clip between the high pressure
pipes between the rail and the injectors.
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.
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 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) .
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.