RENAULT TWINGO 2009 2.G Chasiss Workshop Manual

37A-22
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
RIGHT-HAND DRIVE
37A
aFully lower the engine using the (Mot. 1672).
aPivot the brake servo so that the servo pushrod (15)
is oriented upwards.
aRemove the brake servo by moving the engine for-
ward as far as possible.
aRemove the brake servo from underneath the vehi-
cle.
aRemove the brake servo.
REFITTING
I - REFITTING PREPARATION OPERATION
aCheck that the brake servo seal (16) is in place and
replace the seal if it is faulty.
aThe dual safety connecting shaft between the brake
servo pushrod and the brake pedal must be re-
placed every time it is removed.
aCheck the following dimension before refitting: (X1)
= 132.6 mm. D4F
123847
D4F
K4M
109206
91101

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-24
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
RIGHT-HAND DRIVE
37A
aRefit:
-the brake servo non-return valve (see 37A, Me-
chanical component controls, Brake servo non-
return valve: Removal - Refitting, page 37A-11) ,
-the brake master cylinder (see 37A, Mechanical
component controls, Master cylinder: Removal
- Refitting, page 37A-1) ,
-the fuel vapour recirculation solenoid valve sup-
port,
-the fuel vapour recirculation solenoid valve,
-the fuel vapour recirculation solenoid valve pipes,
-the fuel vapour recirculation solenoid valve con-
nector,
-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 front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) .

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-26
MECHANICAL COMPONENT CONTROLS
Vacuum pump: Removal - Refitting
K9K
37A
III - FINAL OPERATION.
aRefit:
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the engine cover.

37A-27
MECHANICAL COMPONENT CONTROLS
Pedal assembly: List and location of components
37A
I - LIST OF COMPONENTS
The pedal assembly consists of:
-an accelerator pedal (see 37A, Mechanical compo-
nent controls, Accelerator pedal: Removal - Refit-
ting, page 37A-29)
-a brake pedal switch (see 37A, Mechanical compo-
nent controls, Brake pedal switch: Removal - Re-
fitting, page 37A-42)
-a brake pedal (see 37A, Mechanical component
controls, Brake pedal: Removal - Refitting, page
37A-31)
-a brake - clutch pedal assembly (see 37A, Mechani-
cal component controls, Brake pedal: Removal -
Refitting, page 37A-31)
-a clutch pedal switch (see 37A, Mechanical compo-
nent controls, Clutch pedal switch: Removal - Re-
fitting, page 37A-52) II - LOCATION OF COMPONENTS
Accelerator pedal
Brake pedal switch 5-SPEED MANUAL SEQUENTIAL GEARBOX
5-SPEED MANUAL GEARBOX
CRUISE CONTROL
119134
121350

37A-28
MECHANICAL COMPONENT CONTROLS
Pedal assembly: List and location of components
37A
Brake pedal
Brake - clutch pedal assemblyClutch pedal switch 5-SPEED MANUAL SEQUENTIAL GEARBOX
122227
5-SPEED MANUAL GEARBOX
123905
CRUISE CONTROL
121349

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.

37A-30
MECHANICAL COMPONENT CONTROLS
Accelerator pedal: Removal - Refitting
37A
aBond the pedal pad (3) to the pedal (4) by pressing
on the right-hand side.
Press the pad to ensure bonding.
III - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the accelerator pedal,
-the accelerator pedal nuts.
aTorque tighten the accelerator pedal nuts (8 N.m ).
aConnect the accelerator pedal potentiometer con-
nector.
135017
Note:
Respect the range of motion when fitting.

37A-31
MECHANICAL COMPONENT CONTROLS
Brake pedal: Removal - Refitting
RIGHT-HAND DRIVE, and 5-SPEED MANUAL GEARBOX
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the dashboard lower trim (1) ,
-the brake pedal switch (see 37A, Mechanical
component controls, Brake pedal switch: Re-
moval - Refitting, page 37A-42) .
aRemove the accelerator pedal (see 37A, Mechani-
cal component controls, Accelerator pedal: Re-
moval - Refitting, page 37A-29) .aRemove the clutch pedal switch (see ) .
aRemove the dashboard side face (2) .
aDisconnect the airbag inhibitor switch connector (3) . Equipment required
heat str ipper
Tightening torquesm
bolts of the « brake -
clutch pedal assembly » 21 N.m
123870
JB1
CRUISE CONTROL
123870
123871