fuel pressure RENAULT TWINGO 2009 2.G Engine And Peripherals Workshop Manual

TWINGO - Chapitre 1
Contents
Pages
TWINGO - Chapitre 1ContentsPages
10AENGINE AND CYLINDER BLOCK
ASSEMBLY
Crankshaft seal on timing
end: Removal - Refitting 10A-1
Crankshaft seal, gearbox
end: Removal - Refitting 10A-3
Lower cover: Removal -
Refitting 10A-6
Engine oil: Draining -
Refilling 10A-22
Oil filter: Removal - Refitting 10A-29
Oil-coolant heat exchanger:
Removal - Refitting 10A-33
Conrod bearing shell:
Removal - Refitting 10A-37
Oil pressure sensor:
Removal - Refitting 10A-45
Oil pump: Removal -
Refitting 10A-50
Oil pressure: Check 10A-59
Multifunction suppor t:
Removal - Refitting 10A-63
Engine - gearbox assembly:
Removal - Refitting 10A-74
Valves: Adjustment 10A-105
Flywheel: Removal - Refitting 10A-10711A TOP AND FRONT OF ENGINE
Pressure at end of
compression: Check 11A-1
Accessories belt: Removal -
Refitting 11A-3
Crankshaft accessories
pulley: Removal - Refitting 11A-20
Timing belt: Removal -
Refitting 11A-27
Rocker cover: Removal -
Refitting 11A-66
Camshaft: Removal -
Refitting 11A-82
Cylinder head: Removal -
Refitting 11A-114
Camshaft dephaser :
Removal - Refitting 11A-135
Camshaft seal, timing end:
Removal - Refitting 11A-138
Oil decanter: Removal -
Refitting 11A-147
12A FUEL MIXTURE
Air inlet: Description 12A-1
Air filter: Removal - Refitting 12A-6
Air filter unit: Removal -
Refitting 12A-13

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

10A-3
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal, gearbox end: Removal - Refitting
K4M
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-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).
aDrain:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-the engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aRemove:
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the « engine and gearbox » assembly (see 10A,
Engine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) ,
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) (21A, Manual gearbox).
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch),
-the flywheel (see 10A, Engine and cylinder block
assembly, Flywheel: Removal - Refitting, page
10A-107) . Special tooling required
Mot. 1129-01Tool for fitting the crankshaft
seal, flywheel end (80 x 100 x
8 seal).
Equipment required
refrigerant charging station

10A-47
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil pressure sensor: Removal - Refitting
D4F, and 780 or 782
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aUnclip the upstream oxygen sensor wiring harness
from the turbocharger heat shield.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the oil pressure sensor connector (1) .
aRemove the oil pressure sensor (2) .
REFITTING
REFITTING OPERATION FOR PART CONCERNED
aRefit the oil pressure sensor.
aTorque tighten the oil pressure sensor (35 N.m).
aConnect the oil pressure sensor connector.
aClip the upstream oxygen sensor wiring harness
onto the turbocharger heat shield.aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
Tightening torquesm
oil pressure sensor35 N.m
121725

10A-89
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K9K
10A
aUnclip the fuel supply pipes at (12) .
aDisconnect the inlet pipe (13) from the high pressure
pump.
aDisconnect the return pipe (14) from the high pres-
sure pump.
aInsert the blanking plugs.
aUnclip the blower unit wiring.
aDisconnect the connectors from the fan assembly
wiring.
aCut the clip on the battery mounting.aRemove:
-the engine compartment connection unit cover
bolts (15) ,
-the cover of the engine compartment connection
unit.
aDisconnect the connector (16) from the pre-posthe-
ating unit.
121423
WARNING
To prevent impurities from entering the circuit,
plugs must be fitted to the openings of all the fuel
circuit components exposed to the open air.
120324
121429
K9K, and 718
141240

10A-93
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K9K
10A
II - FINAL OPERATION
aRemove the.
aLubricate the seals using recommended air condi-
tioning oil to make fitting easier.
aRefit:
-the connecting pipes to the compressor,
-the connecting pipe union bolts on the compressor,
-the bolt for the connecting pipe mounting on the
compressor.
aConnect:
-the pressostat connector,
-the hose to the coolant pump inlet pipe using the
tool (Mot. 1448).
aFit:
-the hose clip on the coolant pump inlet pipe using
the tool (Mot. 1448),
-the earth on the front left-hand wing.
aRefit the earth nut on the front left-hand wing.
aClip:
-the engine compartment connection unit relay
plates,
-the fuse holders.
aRefit the fuses.
aConnect the preheating unit connector.
aRefit the earth nut on the front left-hand side mem-
ber.
aFit the engine compartment connection unit.
aRefit the engine compartment connection unit
mountings on the body.
aConnect the black connector.
aClip on the black connector.
aRefit:
-the engine compartment connection unit cover,
-a new clip on the battery mounting to hold the elec-
trical wiring.
aConnect the wiring connectors to the fan assembly.aClip the fan assembly wiring.
aRemove the blanking plugs.
aConnect the high pressure pump inlet pipe.
aClip on the fuel supply pipe.
aConnect the high pressure pump return pipe.
aClip on the fuel return pipe.
aRemove the blanking plugs on the clutch hydraulic
control and on the control pipe.
aConnect the clutch hydraulic control to the gearbox.
aClip:
-the clutch control hydraulic pipe on the gearbox,
-the gearbox controls on the cable sleeve stops,
-the gearbox controls on the gear selectors.
aConnect:
-the hoses to the heater radiator,
-the top hose to the water chamber.
aFit:
-the hose clips on the heater radiator using the tool
(Mot. 1448),
-the clip for the top hose on the water chamber us-
ing the tool (Mot. 1448).
aRefit:
-the front section of the intermediate pipe (see 19B,
Exhaust, Intermediate pipe: Removal - Refit-
ting, page 19B-28) ,
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) . WARNING
To prevent any leaks, check that the seal and the
surface of the pipe are in good condition. The
seal and the surface must be clean and scratch
free.

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.

10A-110
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
K4M
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-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).
aDrain:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-the engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).aRemove:
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the « engine - gearbox » assembly (see 10A, En-
gine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) (21A, Manual gearbox),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) ,
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch).
II - REMOVAL OPERATION
aRemove:
-the flywheel bolts,
-the (Mot. 1677) (1) , Special tooling required
Mot. 1677Flywheel locking tool.
Equipment required
refrigerant charging station
Tightening torquesm
flywheel bolts70 N.m
109158

10A-111
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
K4M
10A
-the flywheel.
REFITTING
I - REFITTING PREPARATION OPERATION
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the flywheel bearing face if reusing,
-the crankshaft bearing face.
aAlways replace the flywheel bolts.
II - REFITTING OPERATION
aFit the flywheel.
aFit the new flywheel bolts without tightening them.
aPosition the (Mot. 1677).
aTighten to torque and in order the flywheel bolts
(70 N.m).
III - FINAL OPERATION
aRefit:
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) (21A, Manual gearbox).-the « engine and gearbox » assembly (see 10A,
Engine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) ,
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aPerform the following operations:
-fill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) ,
-fill the gearbox (see Manual gearbox oils: Drain-
ing - Filling) (21A, Manual gearbox).
-fill the refrigerant circuit using a refrigerant charg-
ing station (see Refrigerant circuit: Draining -
Filling) (62A, Air conditioning).
aRefit the engine undertray.
109158

11A-2
TOP AND FRONT OF ENGINE
Pressure at end of compression: Check
D4F
11A
CHECK
I - PREPARATION OPERATION FOR CHECK
aRemove the plugs (see 17A, Ignition, Plugs: Re-
moval - Refitting, page 17A-12) .
aConnect a petrol compression gauge (1) .
aRun command with Diagnostic tool :
-RZ009: VEHICLE FUNCTION PROGRAMMING,
-VP036: FUEL SUPPLY INHIBITION.
aPut the vehicle under the starting conditions by posi-
tioning the gear lever in neutral.II - TEST OPERATION
aActivate the starter until the needle of the petrol
compression gauge stabilises.
aMeasure the cylinder compressions, cylinder by cyl-
inder.
aFully depress the accelerator pedal in order to open
the throttle valve during the compression measure-
ments.
III - FINAL OPERATION
aDisconnect the petrol compression gauge.
aRefit the plugs (see 17A, Ignition, Plugs: Removal
- Refitting, page 17A-12) .
aRun command VP037: "STOP INHIBIT FUEL SUP-
PLY" using the Diagnostic tool.
aStart the engine. Equipment required
petrol compression gauge
Diagnostic tool
Note:
Use a petrol compression gauge compatible with
the special tools.
The petrol compression gauge must be equipped
with a universal end piece (rubber), or a gaz 1/4
thread bolt.
132699
Note:
It is necessar y to wait for at least 10 seconds
before starting the engine each time (the starter
will not run due to its ther mal protection).
Note:
If the engine does not start, run command
VP037: STOP FUEL SUPPLY INHIBITION using
the Diagnostic tool or switch off the ignition and
wait 1 min before starting the engine again.