torque RENAULT TWINGO 2009 2.G Chasiss Workshop Manual

37A-1
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
JB1 or JH1 or JH3 or JR5
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(80A, Battery)
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery).
aRemove:
-the injection computer (see Petrol injection com-
puter: Removal - Refitting) (17B, Petrol injection),
-the injection computer support.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the fuel filler cap from the brake fluid reser-
voir (1) .
aDisconnect the brake fluid level sensor connector (2)
.
aDrain the brake fluid reservoir with a syringe. Tightening torquesm
brake fluid reservoir bolt4 Nm
master cylinder nuts on
the brake servo25 Nm
rigid brake pipe unions
on the master cylinder15 Nm
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
K4M
121344

37A-3
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
JB1 or JH1 or JH3 or JR5
37A
aUsing the workbench, remove:
-the brake fluid reservoir bolt (7) ,
-the brake fluid reservoir.
aFit blanking plugs on the master cylinder.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the master cylinder seals (8) .
aRemove the blanking plugs from the master cylin-
der.
aCarefully pre-fill the master cylinder with the recom-
mended brake fluid (see 30A, General information,
Brake fluid: Specifications, page 30A-18) .II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the brake fluid reservoir,
-the master cylinder making sure that the brake ser-
vo shaft is correctly aligned with the master cylin-
der shaft,
-the rigid brake pipe unions on the master cylinder.
aTighten to torque:
-the brake fluid reservoir bolt (4 Nm),
-the master cylinder nuts on the brake servo (25
Nm),
-the rigid brake pipe unions on the master cylin-
der (15 Nm).
aRemove the blanking plugs from the brake fluid res-
ervoir supply pipe and the clutch master cylinder.
aRefit the clutch master cylinder supply pipe.
aConnect the brake fluid level sensor connector.
III - FINAL OPERATION.
aRefit:
-the injection computer mounting,
-the injection computer (see Petrol injection com-
puter: Removal - Refitting) (17B, Petrol injection).
aFill up the brake fluid reservoir.
aBleed the braking circuit (see 30A, General infor-
mation, Braking circuit: Bleed, page 30A-4) .
aBleed the clutch circuit (see 37A, Mechanical com-
ponent controls, Clutch circuit: Bleed, page 37A-
54) .
aRefit:
-the filler cap of the brake fluid reservoir.
121345
112622
JH3 or JR5
K4M
JH3 or JR5

37A-5
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
RIGHT-HAND DRIVE
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-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 fuel vapour recirculation solenoid valve pipes
(1) ,
-the fuel vapour recirculation solenoid valve con-
nector (2) ,
-the fuel vapour recirculation solenoid valve (3) ,
-the fuel vapour recirculation solenoid valve support
nut (4) ,
-the fuel vapour recirculation solenoid valve support
(5) . Tightening torquesm
brake fluid reservoir bolt4 Nm
master cylinder bolts on
the brake servo25 Nm
rigid brake pipe unions
on the master cylinder15 Nm
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
D4F or D7F or K4M
123852

37A-9
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
RIGHT-HAND DRIVE
37A
aRemove:
-the clip (17) from the reservoir connecting pipe,
-the reservoir connecting pipe (18) ,
-the rigid brake pipe unions (19) on the master cylin-
der,
-the master cylinder nuts (20) on the brake servo,
-the “master cylinder - reservoir” assembly.
aFit blanking plugs to the master cylinder, the main
brake fluid reservoir supply pipe and the brake fluid
reservoir connecting pipe.
aRemove:
-the bolt (21) from the main brake fluid reservoir,
-the main brake fluid reservoir from the master cylin-
der.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the master cylinder seals (22) .
aRemove the blanking plugs from the master cylin-
der, the main brake fluid reservoir supply pipe and
the brake fluid reservoir connecting pipe.
aCarefully pre-fill the master cylinder with the recom-
mended brake fluid (see 30A, General information,
Brake fluid: Specifications, page 30A-18) .
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the brake fluid reservoir to the master cylinder,
-the "master cylinder - reservoir" assembly, aligning
the brake servo shaft with the master cylinder
shaft,
-the rigid brake pipe unions on the master cylinder.
aTighten to torque:
-the brake fluid reservoir bolt (4 Nm),
-the master cylinder bolts on the brake servo (25
Nm),
-the rigid brake pipe unions on the master cylin-
der (15 Nm).
aRefit:
-the brake fluid reservoir connecting pipe,
-the brake fluid reservoir connecting pipe clip.
123849
112622

37A-14
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
JB1 or JH1 or JH3 or JR5, and LEFT-HAND DRIVE
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aRemove the gearbox computer (see Sequential
gearbox converter: Removal - Refitting) (21B,
Sequential gearbox).
aRemove the battery tray (see Battery tray: Remov-
al - Refitting) (80A, Battery).
aRemove the petrol injection computer (see Petrol
injection computer: Removal - Refitting) (17B,
Petrol injection).
aRemove the diesel injection computer (see Diesel
injection computer: Removal - Refitting) (13B,
Diesel injection).
aRemove:
-the injection computer mounting bolts (1) ,
-the engine harness bracket nut (2) ,
-the injection computer mounting,
-the master cylinder (see 37A, Mechanical compo-
nent controls, Master cylinder: Removal - Refit-
ting, page 37A-1) . Tightening torquesm
brake servo nuts25 Nm
JH1
D4F or D7F or K4M
K9K
122323
122322

37A-17
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
JB1 or JH1 or JH3 or JR5, and LEFT-HAND DRIVE
37A
aCheck that the brake servo seal (5) is in place and
replace the seal if it is faulty.
aBefore refitting, check the dimension L = 153.3 mm.
aIf the dimension is not correct, replace the brake ser-
vo.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the brake servo,
-the brake servo nuts (3) .aTorque tighten the brake servo nuts (25 Nm).
aRefit the new connecting shaft (3) between the
brake pedal and the brake servo rod from right to left
and from top to bottom.
III - FINAL OPERATION.
aRefit:
-the non-return valve on the brake servo,
-the master cylinder (see 37A, Mechanical compo-
nent controls, Master cylinder: Removal - Refit-
ting, page 37A-1) ,
-the injection computer mounting,
-the engine wiring bracket.
aRefit the petrol injection computer (see Petrol injec-
tion computer: Removal - Refitting) (17B, Petrol
injection).
aRefit the diesel injection computer (see Diesel in-
jection computer: Removal - Refitting) (13B, Die-
sel injection).
109206
91101-1
109205
D4F or D7F or K4M
K9K

37A-19
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
RIGHT-HAND DRIVE
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-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 fuel vapour recirculation solenoid valve pipes
(1) ,
-the fuel vapour recirculation solenoid valve con-
nector (2) ,
-the fuel vapour recirculation solenoid valve (3) ,
-the fuel vapour recirculation solenoid valve support
bolt (4) ,
-the fuel vapour recirculation solenoid valve support
(5) ,
-the brake master cylinder (see 37A, Mechanical
component controls, Master cylinder: Removal
- Refitting, page 37A-1) ,
-the brake servo non-return valve (see 37A, Me-
chanical component controls, Brake servo non-
return valve: Removal - Refitting, page 37A-11) .
aRemove the ignition coil (see Coils: Removal - Re-
fitting) (17A, Ignition). Special tooling required
Mot. 1672Low er engine support.
Equipment required
refrigerant charging station
Tightening torquesm
“brake - clutch pedal”
assembly nuts21 Nm
brake servo nuts21 Nm
123852
D4F or D7F

37A-23
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
RIGHT-HAND DRIVE
37A
II - REFITTING OPERATION FOR PART
CONCERNED
aPosition the brake servo by moving the engine for-
ward as far as possible and tilting the pushrod up-
wards.
aRefit the brake servo from underneath the vehicle.
aRefit the brake servo.
aPosition the “brake - clutch pedal” assembly on the
bulkhead.
aTorque tighten the “brake - clutch pedal” assem-
bly nuts (21 Nm).
aRefit:
-the new dual safety connecting shaft between the
brake servo pushrod and the brake pedal from right
to left and from top to bottom,
-the brake servo nuts.
aTorque tighten the brake servo nuts (21 Nm).
III - FINAL OPERATION.
aRefit:
-the clutch master cylinder support,
-the clutch master cylinder support bolts,
-the clutch master cylinder rod on the clutch pedal.
aRefit the exhaust manifold (see Exhaust manifold:
Removal - Refitting) (12A, Fuel mixture).aRefit the catalytic converter (see Catalytic convert-
er: Removal - Refitting) (19B, Exhaust).
aRefit:
-the right-hand suspended engine mounting (see
Right-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting).
aRefit:
-the air filter box heat-resistant protector,
-the air filter box heat-resistant protector bolts,
-the air filter (see Air filter: Removal - Refitting)
(12A, Fuel mixture).
aRefit the "dehydrator reservoir - expansion valve"
connection (see Dehydrator reservoir - expansion
valve connecting pipe: Removal - Refitting) (62A,
Air conditioning).
aFill the refrigerant circuit using a refrigerant charg-
ing station (see Refrigerant circuit: Draining -
Filling) (62A, Air conditioning).
aRefit the ignition coil (see Coils: Removal - Refit-
ting) (17A, Ignition). D4F
K4M
JH3 or JR5
K4M
D4F, and 780
D4F
D7F
AIR CONDITIONING or CLIMATE CONTROL
D4F or D7F

37A-25
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting
K9K
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the engine cover,
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the brake servo pipe (1) from the vacu-
um pump.aRemove:
-the vacuum pump bolts (2) ,
-the vacuum pump (3) ,
-the vacuum pump seal.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aClean the vacuum pump sealing surface.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the vacuum pump seal,
-the vacuum pump,
-the vacuum pump bolts.
aTorque tighten the vacuum pump bolts (25 Nm).
aConnect the brake servo pipe onto the vacuum
pump. Tightening torquesm
vacuum pump bolts25 Nm
121356
121355
WARNING
The seals m ust always be replaced.

37A-29
MECHANICAL COMPONENT CONTROLS
Accelerator pedal: Removal - Refitting
37A
REMOVAL
I - REMOVAL OPERATION FOR ALUMINIUM
PEDAL PAD
aHeat the pedal pad with a heat stripper to a maxi-
mum temperature of 80˚C.
aRemove the pad using a pair of pliers.
aClean the residue of adhesive on the pedal (see
Tools for stripping very thick soft mastic: Use) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the accelerator pedal potentiometer con-
nector (1) .
aRemove:
-the accelerator pedal nuts (2) ,-the accelerator pedal.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the aluminium pedal pad each time it
is removed.
II - REFITTING OPERATION FOR ALUMINIUM
PEDAL PAD
aCheck that the pedal is at ambient temperature.
aCheck that the surface of the pedal is clean.
aActivate the pedal bonding surface with some paper
soaked in HEPTANE.
Wipe immediately with a clean and dry cloth.
Remove the protection around the pad. Equipment required
heat str ipper
Tightening torquesm
accelerator pedal nuts8 N.m
EQ UIPMENT LEVEL SPORT
119134
EQUIPMENT LEVEL SPORT
EQUIPMENT LEVEL SPORT
Note:
If only the pad is being replaced, allow the pedal
to cool.
Note:
The bonding area must be clean, and free from
finger mar ks and fabric deposits.
Note:
It is essential to activate the surface and to wipe
in the same direction: there is a risk of contami-
nating the bonding surface when wiping.
Note:
Do not use the same paper to activate the sur-
face and to wipe the surface.
Throw the paper away after each use.