Injector rail RENAULT TWINGO 2009 2.G Engine And Peripherals Workshop Manual

Contents
Air resonator : Removal -
Refitting 12A-19
Throttle valve: Removal -
Refitting 12A-20
Throttle valve: Cleaning 12A-26
Air flowmeter: Removal -
Refitting 12A-28
Inlet distributor: Removal -
Refitting 12A-29
Injector holder shim:
Removal - Refitting 12A-45
Exhaust manifold: Removal -
Refitting 12A-48
12B TURBOCHARGING
Turbocharging: Precautions
for the repair 12B-1
Turbocharger: Removal -
Refitting 12B-4
Turbocharger oil pipe:
Removal - Refitting 12B-12
Intercooler : Removal -
Refitting 12B-18
13A FUEL SUPPLY
Diesel supply circuit:
Operating diagram 13A-1
Manual pr iming pump:
Removal - Refitting 13A-2
Fuel filter : Removal -
Refitting 13A-4
Electric diesel fuel heater:
Removal - Refitting 13A-7
Fuel circuit: Operating
diagram 13A-8 12A FUEL MIXTUREFuel pressure: Check 13A-9
Fuel flow: Check 13A-14
13B DIESEL INJECTION
Diesel injection: Precautions
for the repair 13B-1
Diesel injection: List and
location of components 13B-8
Diesel injection computer:
Removal - Refitting 13B-13
Camshaft position sensor:
Removal - Refitting 13B-14
Crankshaft position sensor:
Removal - Refitting 13B-15
High pressure pump:
Removal - Refitting 13B-16
Flow actuator: Removal -
Refitting 13B-26
Venturi: Removal - Refitting 13B-31
High pressure pipe: Check 13B-34
High pressure pipe between
pump and rail: Removal -
Refitting 13B-35
High pressure pipe between
rail and injector: Removal -
Refitting 13B-39
Injector rail: Removal -
Refitting 13B-43
Rail pressure sensor:
Removal - Refitting 13B-48
Fuel temperature sensor:
Removal - Refitting 13B-49
Injector leak flow: Check 13B-51
Accelerometer : Removal -
Refitting 13B-53 13A FUEL SUPPLY

Contents
13C PREHEATING
Pre-postheating unit:
Removal - Refitting 13C-1
Heater plugs: Removal -
Refitting 13C-2
14A ANTIPOLLUTION
Oil vapour rebreathing
circuit: Descriptions 14A-1
Fuel vapour recirculation
circuit: Operating diagram 14A-2
Fuel vapour recirculation
circuit: Check 14A-3
Fuel vapour absorber:
Removal - Refitting 14A-4
Fuel vapour absorber: Check 14A-7
Fuel vapour absorber bleed
solenoid valve: Removal -
Refitting 14A-8
Exhaust gas recirculation
solenoid valve: Removal -
Refitting 14A-10
Exhaust gas cooler: Removal
- Refitting 14A-11
Exhaust gas recirculation
assembly: Removal -
Refitting 14A-15
Exhaust gas recirculation
rigid pipe: Removal -
Refitting 14A-19
16A STARTING - CHARGING
Alternator: Removal -
Refitting 16A-1
Star ter: Removal - Refitting 16A-10
Alternator pulley: Removal -
Refitting 16A-1717A IGNITION
Coils: Removal - Refitting 17A-1
Plugs: Removal - Refitting 17A-12
17B PETROL INJECTION
Petrol injection: List and
location of components 17B-1
Oxygen sensors: Removal -
Refitting 17B-13
Petrol injection computer:
Removal - Refitting 17B-20
Pinking sensor: Removal -
Refitting 17B-23
Crankshaft position sensor:
Removal - Refitting 17B-25
Injector rail - Injectors:
Removal - Refitting 17B-27
19A COOLING
Engine cooling system:
Specifications 19A-1
Engine cooling system:
Check 19A-2
Engine cooling circuit: List
and location of components 19A-4
Engine cooling system:
Operating diagram 19A-5
Cooling system: Draining -
Refilling 19A-9
Cooling radiator: Removal -
Refitting 19A-12
Coolant pump: Removal -
Refitting 19A-24
Thermostat: Removal -
Refitting 19A-34
Water chamber: Removal -
Refitting 19A-40

10A-103
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
-the rubber pad mounting from the suspended en-
gine mounting on the gearbox.
aRemove the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aLift the vehicle to remove the "engine and gearbox"
assembly.
REFITTING
I - REFITTING PREPARATION OPERATION
aFor standard engine replacement (see Standard re-
placement) (Technical Note 6023A, 10A, Engine
and peripherals).
II - REFITTING OPERATION
aPosition the "engine and gearbox" assembly in the
body.
aRefit the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aRefit the rubber pad mounting from the suspended
engine mounting on the gearbox.
aTorque tighten the rubber pad mounting bolts for
the suspended engine mounting on the gearbox
(21 N.m).
aRefit the suspended engine mounting rubber pad.
aTorque tighten:
-the bolts of the suspended mounting rubber
pad (62 N.m),
-the suspended engine mounting shaft nut (62
N.m).
III - FINAL OPERATION
aRemove the.
aRemove the blanking plugs.
aConnect:
-the union of the brake servo vacuum pipe,
-the « compressor - condenser » connecting pipe,-the « compressor - intermediate pipe » connecting
pipe,
-the pressure sensor connector,
aConnect the hose on the coolant pump inlet pipe.
aFit the hose clip on the coolant pump inlet pipe using
the (Mot. 1448).
aRefit the earth nuts.
aClip:
-the relay plates on the engine compartment con-
nection unit,
-the fuse holders.
aConnect the fuses.
aRefit the engine compartment connection unit on the
body.
aConnect the connector to the engine compartment
connection unit.
aRefit the engine compartment connection unit cover.
aClip:
-the wiring on the engine cooling fan assembly,
-the cooling radiator top and bottom hoses on the
engine cooling fan assembly.
aConnect:
-the engine cooling fan assembly resistor connec-
tor,
-the engine cooling fan assembly connector.
aRemove the blanking plug from the fuel supply pipe
opening and the injector rail fuel opening.
aReconnect the fuel supply pipe.
aClip the fuel supply pipe in place.
aConnect:
-the fuel vapour absorber bleed solenoid valve con-
nector,
-the fuel vapour absorber bleed solenoid valve pipe.
aFit the gearbox control cables.
aClip the manual gearbox control cables onto:
-the gear selectors,
-the cable sleeve stops.
aRemove the blanking plug from the hydraulic clutch
control pipe opening and the opening of the clutch
thrust bearing.
aConnect the hydraulic clutch control pipe.
aClip the hydraulic clutch control pipe on the gearbox. Note:
Check no component obstructs the movement of
the body around the engine - gearbox assembly.

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

11A-131
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
aRemove the bolts (2) on the intercooler outlet air
pipe.
aMove the intercooler outlet air pipe away from the
throttle valve.
aUndo the compressor discharge valve air pipe clip
(3) .
aDisconnect:
-the turbocharging solenoid valve connector to the
turbocharger,
-the compressor discharge valve air pipe from the
air filter unit outlet air pipe.aUnclip the injection wiring from the inlet manifold.
aDisconnect:
-the upstream oxygen sensor connector (4) .
-the air inlet pressure connector (5) ,
-the injector rail - injector wiring connector (6) ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the throttle body connector ,
-the coolant temperature sensor connector.
aDisconnect the petrol supply union on the injector
rail - injector.
aPlug the openings.
aMove aside the engine wiring.
122390121765
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-133
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
2 - Checking the gasket face
aCheck the flatness of the cylinder head gasket face
(see Cylinder head: Check) .
3 - Optional additional operations
aWhen replacing the cylinder head, strip the cylinder
head (see Cylinder head: Stripping - Rebuilding) .
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.
aCheck for the cylinder head centring dowels on the
cylinder block.
aFit a new cylinder head gasket onto the cylinder
block, positioning the marking (8) on the oil filter
side.
aRefit 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) (20 N.m).
aCheck that the cylinder head bolts are tightened to
20 N.m.
aAngle tighten in order the cylinder head bolts (230˚
±± ± ±
6˚).
III - FINAL OPERATION
aConnect the cooling hoses.
aRefit:
-the cooling hose clips using the (Mot. 1448),
-the engine wiring.
aRemove the blanking plugs.
aConnect:
-the petrol inlet union on the injector rail - injectors.
-the coolant temperature sensor connector,
-the throttle body connector ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the injector rail - injector wiring connector,
-the air inlet pressure connector.
-the upstream oxygen sensor connector.
aClip the injection wiring onto the inlet manifold.
aConnect:
-the compressor discharge valve air pipe to the air
filter unit outlet air pipe, WARNING
No regrinding of the cylinder head is permitted.
19598
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.
18641

12A-29
FUEL MIXTURE
Inlet distributor: Removal - Refitting
D7F
12A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aParts always to be replaced
-inlet distributor seals.
aConsumables (see Vehicle: Parts and consuma-
bles for the repair)
-FLUOSTAR 2L grease.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the air inlet scoop on the front end panel,
-the air filter unit air inlet pipe,
-the air filter unit air outlet pipe.
aDisconnect the motorised throttle valve connector.aRemove:
-the intermediate bracket bolts on the throttle valve,
-the intermediate plate,
-the motorised throttle valve bolts (1) ,
-the motorised throttle valve. Tightening torquesm
injector rail bolts7 N.m
motorised throttle valve
bolts10 N.m
inlet distributor nuts on
the cylinder head (initial
torque)8 N.m
inlet distributor bolts on
the rocker cover (initial
torque)3 N.m
inlet distributor nuts on
the cylinder head17 N.m
inlet distributor bolts on
the rocker cover10 N.m
motorised throttle valve
bolts10 N.m
120406

12A-31
FUEL MIXTURE
Inlet distributor: Removal - Refitting
D7F
12A
aRemove:
-the air inlet distributor bolts on the rocker cover (9) ,
-the inlet distributor.
When replacing the inlet distributor
aRemove:
-the fuel supply pipe from the injector rail,
-the injector rail bolts,
-the injector rail.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the inlet distributor seals.
When replacing the inlet distributor
aRefit:
-the injector rail fuel supply pipe on the inlet distrib-
utor,
-the injector rail,
-the injector rail bolts.
aTorque tighten the injector rail bolts (7 N.m).
aRefit:
-the motorised throttle valve with a new seal,
-the motorised throttle valve bolts.
aTorque tighten the motorised throttle valve bolts
(10 N.m).II - REFITTING OPERATION FOR PART
CONCERNED
aFit the inlet distributor with new seals
aFit without tightening:
-the inlet distributor nuts on the cylinder head,
-the inlet distributor bolts on the rocker cover.
aPre-tighten to torque:
-the inlet distributor nuts on the cylinder head
(initial torque) (8 N.m),
-the inlet distributor bolts on the rocker cover
(initial torque) (3 N.m).
aTorque tighten:
-the inlet distributor nuts on the cylinder head
(17 N.m),
-the inlet distributor bolts on the rocker cover
(10 N.m).
III - FINAL OPERATION
aConnect:
-the oil vapour induction pipe from inlet distributor ,
-the fuel supply pipe intermediate union,
-the injector connectors,
-the air temperature sensor connector,
-the air inlet pressure sensor connector,
-the non-return valve pipe on the inlet distributor,
-the petrol vapour rebreather pipe.
121735