2009 RENAULT TWINGO lock

12B-1
TURBOCHARGING
Turbocharging: Precautions for the repair
D4F or K9K
12B
I - TURBOCHARGER: GENERAL INSTRUCTIONS
For the turbocharging pressure regulator check (see
Fault finding - Tests) (Technical Note 3419A, 12B,
Turbocharging).
II - TURBOCHARGER CIRCUIT DIAGRAMIII - APPLICATION CONDITIONS OF
INSTRUCTIONS
The instructions below must be followed when repla-
cing a turbocharger due to mechanical damage:
-damage to the bearing system,
-broken shaft or turbine wheel,
-compressor wheel rubbing against the turbocharger
casing,
-broken or damaged compressor wheel,
-extensive clogging of the turbine wheel casing (hard
deposits).
FOR THE AIR CIRCUIT:
-Consequences:
•swarf or metal objects in the turbocharger inlet and
outlet pipes,
•oil in the air circuit (collected in the intercooler).
-Risks (after replacing the turbocharger):
•metal objects sucked in by the compressor wheel
(destruction of the turbocharger).
FOR THE LUBRICATION CIRCUIT:
-Consequences:
•swarf found in the engine oil circuit,
•circulation of swarf within the circuit.
-Risks (after replacing the turbocharger):
•premature wear on the bearing system (destruction
of turbocharger).
INSTRUCTIONS:
-Drain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22)
-Replace the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29) .
-Replace the seals and fittings,
-Carry out the following only if the compressor wheel is
broken or rubbing against the turbocharger casing:
•Drain the intercooler, Equipment required
par ts washer
WARNING
The turbocharger pressure regulator rod must not
be adjusted.
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(1) Air filter unit
(2) Air flowmeter
(3) Compressor wheel
(4) Intercooler
(5) Inlet distributor
(6) Exhaust manifold
(7) Turbine wheel
(8) Bearing system (bearing +
wheel shaft)
(A) Air filter box air outlet pipe
(B) Turbocharger air outlet pipe
(C) Intercooler air outlet pipe
WARNING
Metal objects may enter the oil and air circuits as a
result of a broken turbocharger.
Failure to follow the INSTRUCTIONS listed will lead
to the turbocharger breaking again.

12B-3
TURBOCHARGING
Turbocharging: Precautions for the repair
D4F or K9K
12B
One by one, clean the pipes removed with the parts
washer :
-brush as much of the inside of the pipe as possible
(only use brushes with plastic bristles),
-wash plenty of cleaning product from the cleaning sta-
tion through the pipe,
-allow the cleaned pipe to drain by standing it upright,
-ensure the cleaning product has drained out com-
pletely (check areas where liquid may be retained,
e.g. gaiters, resonators etc.).
Dry the pipes one by one using a compressed air spray
gun.
For pipes comprising several components:
-assemble the components, taking note of their correct
fitting position (10) .
Refit:
-the air pipe(between the air filter unit and the turbo-
charger) (A) ,
-the air pipe (B) (between the turbocharger and the in-
tercooler).
Refit the intercooler, if fitted to the vehicle (see 12B,
Turbocharging, Intercooler: Removal - Refitting,
page 12B-18) .V - LUBRICATION CIRCUIT**: INSTRUCTIONS
FOLLOWING MECHANICAL DAMAGE TO THE
TURBOCHARGER
Drain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) .
Replace the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting, page
10A-29) .
Only fill the engine with a suitable oil type (see Engine
oil: Specifications) (Technical Note 6013A, 04A, Lu-
bricants).
VI - GENERAL INSTRUCTIONS TO BE FOLLOWED
WHEN REMOVING A TURBOCHARGER
Always replace:
-the oil supply pipe:
•if the pipe is blocked, even partially (due to scale,
carbonised oil etc.),
•if the pipe is fitted with self-retaining seals.
-the oil return pipe:
•if the pipe is blocked, even partially (due to scale,
carbonised oil etc.),
•if the pipe is fitted with self-retaining seals.
-all seals that have been removed,
-all fittings that have been removed.
When starting the engine:
-do not accelerate,
-allow the engine to run for 1 minute,the time taken for
the oil circuit pressure to increase (until the oil pres-
sure warning light on the instrument panel goes out),
-accelerate several times at no load,
-check the air circuit and the oil circuit for leaks.
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Note:
(**) These instructions relating to the lubrication cir-
cuit must always be followed in all cases of
mechanical damage as listed above.
WARNING
Failure to observe the following procedure may lead
to destr uction of the turbocharger.

12B-10
TURBOCHARGING
Turbocharger: Removal - Refitting
D4F, and 780 or 782
12B
aLoosen the clip of the air filter unit air outlet pipe.
aRemove:
-the air outlet pipe of the air filter unit,
-the turbocharger cooling pipe bracket bolt,
-the turbocharger cooling hollow pipe bolts,
-the turbocharger cooling pipes.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Turbocharger nut.
aparts always to be replaced: seal between ex-
haust manifold and turbocharger.
aparts always to be replaced: Turbocharger cool-
ant pipe if replacing the turbocharger.
aUse a SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease the sealing
surfaces:
-of the turbocharger (if being reused),
-of the exhaust manifold.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-a new turbocharger seal,
-the turbocharger,
-new turbocharger nuts.
aTorque tighten the turbocharger nuts (21 N.m).
1 - If replacing the turbocharger
aRefit:
-the turbocharger cooling pipes,
-the turbocharger cooling hollow pipe bolts,
-the turbocharger cooling pipe bracket bolts,-the air outlet pipe of the air filter unit.
aTighten the clip of the air outlet pipe on the air filter
unit.
aTorque tighten:
-the turbocharger cooling pipe hollow bolts (30
N.m),
-the turbocharger cooling pipe bracket bolts (10
N.m).
a
aConnect the turbocharging pressure regulation
pipes.
aClip on the clips of the turbocharging pressure regu-
lation pipes.
2 - If the turbocharger is not being replaced
aClip the wiring onto the turbocharger coolant rigid
pipe strut.
aConnect:
-the turbocharger discharge air pipe,
-the oil vapour recirculation pipe on the air filter unit
air outlet pipe,
-the petrol vapour recirculation pipe on the air filter
unit air outlet pipe,
-the turbocharging regulation solenoid valve con-
nector from the turbocharger,
-the ignition coil connector.
aTighten the turbocharger discharge air pipe clip.
aRefit the turbocharger oil supply pipe (see 12B, Tur-
bocharging, Turbocharger oil pipe: Removal -
Refitting, page 12B-12) .
aRefit the turbocharger cooling pipe strut bolt.
aConnect the turbocharger cooling hoses.
aFit the turbocharger cooling hose clips using the tool
(Mot. 1448).
aRemove the tools (Ms. 583).
aRefit the turbocharger oil return pipe (see 12B, Tur-
bocharging, Turbocharger oil pipe: Removal -
Refitting, page 12B-12) . WARNING
Ensure that no foreign bodies enter the turbine or
compressor during the refitting operation.
Check that the turbocharger oil return pipe is not
partially or completely blocked by scale. Check
that there are no leaks. If there are, replace the
part.Note:
Dur ing this operation, use a set of feeler gauges
to ensure that there is a minimum clearance of 3
mm between the turbocharger water outlet pipe
and the turbocharger heat shield.

12B-12
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting
D4F, and 780 or 782
12B
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 Battery: Removal - Re-
fitting) (80A, Battery).
aRemove:
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the air filter box strut bolt,
-the air filter box strut,
-the upstream oxygen sensor (see 17B, Petrol in-
jection, Oxygen sensors: Removal - Refitting,
page 17B-13) . Tightening torquesm
turbocharger oil return
pipe bolts10 N.m
turbocharger oil supply
pipe bolt on the cylinder
block19 N.m
turbocharger oil supply
pipe bolt on the turbo-
charger19 N.m
turbocharger oil supply
pipe bolt10 N.m

12B-13
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting
D4F, and 780 or 782
12B
a
aRemove the turbocharger air outlet pipe bolt (3) on
the throttle valve.
aUnclip the turbocharger air outlet pipe on the turbo-
charger in the direction of the arrow (4) .
aDisconnect the turbocharger air outlet pipe from theturbocharger.
aMove aside the turbocharger air outlet pipe.
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the lower bolts from the heat shield,
-the upper bolts from the heat shield,
-the heat shield.
1 - Oil supply pipe
aRemove:
-the bolt (6) from the turbocharger oil supply pipe on
the turbocharger,
-the bolt (7) on the turbocharger oil supply pipe on
the cylinder block,
-the turbocharger oil supply pipe bolt (8) ,
-the turbocharger oil supply pipe.
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122673
Note:
If the turbocharger air outlet pipe tightening clip
(1) is removed, the flexible rubber pipe (2) and
the tightening clip (1) must be replaced.
Note:
If the clip (5) is removed from the heat resistant
protector, the latter must be replaced.
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12B-14
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting
D4F, and 780 or 782
12B
2 - Oil return pipe
aRemove:
-the bolts (9) from the turbocharger oil return pipe,
-the turbocharger oil return pipe.
aFit a blanking plug to the opening on the cylinder
block after removal of the turbocharger oil return
pipe.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Turbocharger oil
pipe.
aRemove the protective plug from the opening on the
cylinder block.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the new turbocharger oil return pipe fitted with new
seals,
-the turbocharger oil return pipe bolts.
aTorque tighten the turbocharger oil return pipe
bolts (10 N.m).
aRefit:
-the new turbocharger oil supply pipe fitted with its
new seals,-the turbocharger oil supply pipe bolt on the cylinder
block,
-the turbocharger oil supply pipe bolt on the turbo-
charger,
-the turbocharger oil supply pipe bolt.
aTorque tighten:
-the turbocharger oil supply pipe bolt on the cyl-
inder block (19 N.m),
-the turbocharger oil supply pipe bolt on the tur-
bocharger (19 N.m),
-the turbocharger oil supply pipe bolt (10 N.m).
aRefit:
-the heat shield,
-the upper bolts from the heat shield,
-the lower bolts of the heat shield.
III - FINAL OPERATION
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .
aFit the turbocharger air outlet pipe.
aPush the clip of the turbocharger air outlet pipe (10) .
aConnect the turbocharger air outlet pipe to the turbo-
charger.
aRefit the turbocharger air outlet pipe bolt on the
throttle valve.
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12B-17
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting
C44, and K9K
12B
2 - Oil return pipe
aRemove the bolts (3) of the oil return pipe from the
turbocharger.
aIn the direction of the arrows, rotate the oil return
pipe of the turbocharger to facilitate its removal.
aRemove the turbocharger oil pipe from the cylinder
block.
REFITTING
I - REMOVAL PREPARATION OPERATION
aAlways replace:
-the turbocharger oil supply pipe,
-the flat seal of the oil return pip on the turbocharg-
er,
-the O-ring of the oil return pip on the turbocharger.
aLubricate the O-ring of the oil return pipe on the tur-
bocharger with engine oil.
II - REFITTING OPERATION FOR PART
CONCERNED
1 - Turbocharger oil supply pipe
aFit the turbocharger oil supply pipe.
aRefit:
-the turbocharger oil supply pipe nut on the cylinder
head,-the bolt of the turbocharger oil supply pipe onto the
turbocharger.
aTorque tighten:
-the nut of the oil supply pipe on the cylinder
head ( 35 Nm) using the (Mot. 1746),
-the bolt of the turbocharger oil supply pipe on
the turbocharger (14 Nm).
2 - turbocharger oil return pipe
aFit the oil return pipe on the cylinder block.
aRefit the turbocharger oil return pipe bolts.
aTorque tighten the turbocharger oil return pipe
bolts (12 N.m).
III - FINAL OPERATION.
1 - Turbocharger oil supply pipe
aRefit:
-the exhaust gas recirculation solenoid valve (see
14A, Antipollution, Exhaust gas recirculation
solenoid valve: Removal - Refitting, page 14A-
10) ,
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-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).
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
2 - turbocharger oil return pipe
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aRefit the engine cover.
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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.
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Note:
Make preparations for fuel outfl ow.
120045