lock RENAULT TWINGO 2009 2.G Chasiss Workshop Manual

© Renault s.a.s 2007 "The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are
constructed".All rights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part reference
numbering system is forbidden without the prior written authority of Renault.
NOVEMBER 2009 EDITION ANGLAISE
X44
3Chassis
30AGENERAL INFORMATION
31AFRONT AXLE COMPONENTS
33AREAR AXLE COMPONENTS
35AWHEELS AND TYRES
36ASTEERING ASSEMBLY
36BPOWER ASSISTED STEERING
37AMECHANICAL COMPONENT CONTROLS
38CANTI-LOCK BRAKING SYSTEM

Contents
37A MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal -
Refitting 37A-1
Brake servo non-return
valve: Removal - Refitting 37A-11
Brake servo: Remo val -
Refitting 37A-14
Vacuum pump: Removal -
Refitting 37A-25
Pedal assembly: List and
location of components 37A-27
Accelerator pedal: Removal -
Refitting 37A-29
Brake pedal: Removal -
Refitting 37A-31
Brake pedal switch: Removal
- Refitting 37A-42
Parking br ake lever: Removal
- Refitting 37A-46
Parking brake lever:
Adjustment 37A-48
Clutch control: List and
location of components 37A-49
Clutch cable: Removal -
Refitting 37A-51
Clutch pedal switch:
Removal - Refitting 37A-52
Clutch circuit: Bleed 37A-54
Clutch master cylinder:
Removal - Refitting 37A-61
Clutch circuit: Removal -
Refitting 37A-63
Manual gear control: List and
location of components 37A-65
Gear control unit: Removal -
Refitting 37A-67
Gear control unit: Adjustment 37A-71
Parking brake cables:
Removal - Refitting 37A-74
Brake servo: Check 37A-7838C ANTI-LOCK BRAKING SYSTEM
Hydraulic brake unit: List and
location of components 38C-1
Hydraulic brake unit:
Removal - Refitting 38C-2
Front wheel speed sensor:
Removal - Refitting 38C-15
Rear wheel speed sensor :
Removal - Refitting 38C-17
Lateral acceleration and yaw
sensor: Removal - Refitting 38C-19
Braking computer: Removal -
Refitting 38C-21

30A-18
GENERAL INFORMATION
Brake fluid: Specifications
30A
BRAKE FLUID REPLACEMENT INTERVAL
Our braking technology, and in particular the disc
brakes (hollow pistons which conduct little heat, have a
low volume of fluid in the cylinder, sliding callipers
avoiding the need for a fluid reserve in the least cooled
area of the wheel), has allowed us to prevent the risk of
« vapour lock » as far as possible, even with heavy
braking (mountainous area). However, current brake
fluids are subject to minor deterioration during the first
months of use due to slight humidity intake. This is why
it is recommended that you change the brake fluid: see
maintenance booklet for the vehicle.
1 - Topping up the level
Wear of the brake pads will result in a gradual drop in
the fluid level in the reservoir.
Do not top up the fluid, as the level will rise again when
the pads are next changed. The brake fluid level must
not fall below the minimum mark.
2 - Approved brake fluid
Mixing two incompatible brake fluids in the brake circuit
may lead to:
-serious risk of leakage due mainly to deterioration of
the cups,
-deterioration in the operation of the ESP system.
To prevent such risks, it is essential to use only brake
fluids that comply with the RENAULT standard (see
Vehicle: Parts and consumables for the repair) .

30A-22
GENERAL INFORMATION
Steering: Tightening torque
30A
(6) Wheel bolt 105
(7) Wheel alignment lock nut 53 No. Description Tightening torque (Nm)

30A-23
GENERAL INFORMATION
Axle assemblies: Check
30A
aLock the slip plates of the lift.
aPosition the vehicle on a lift (see Vehicle: Towing
and lifting) .
aCheck the condition of the following components:
-track rods,
-axial ball joint linkages,
-subframe,
-lower arm rubber bushes,
-lower arm ball joints (see Front driveshaft lower
arm ball joint: Check) ,
-shock absorbers,
-tyres,
aCheck:
-the tyre size (see 35A, Wheels and tyres, Tyres:
Identification, page 35A-7) ,
-the tyre inflation pressure (see 35A, Wheels and
tyres, Tyre pressure: Identification, page 35A-
10) .
aPut the vehicle in the VODM position (vehicle in run-
ning order) (see 30A, General information, Under-
body heights: Adjustment value, page 30A-24) :
-tank full,
-vehicle empty (without luggage, etc.).
aConsult:
-the front axle geometry values (see 30A, General
information, Front axle assembly: Adjustment
values, page 30A-31) ,
-the rear axle geometry values (see 30A, General
information, Rear axle assembly: Adjustment
values, page 30A-38) .
aRefer to the user manual for the geometry tester.
aCheck the geometry using the geometry tester.
aIf there is an inconsistency between the manufactur-
er's values and the measured values:
aAdjust the front axle (see 30A, General informa-
tion, Front axle system: Adjustment, page 30A-
36)

30A-30
GENERAL INFORMATION
Front axle system: Tightening torque
30A
119649
No. DescriptionTightening torque
(N.m)
(1) Impact bracket bolts 21
(2) Impact bracket bolts 90
(3) Acoustic tie-rod nuts 62
(4) Acoustic tie-rod bolts 21
(5) Subframe rear bolt 105
(6) Subframe front bolts 62
(7) Anti-roll bar bearing bolts on the
subframe35
(8) Anti-roll bar bolt on the wheel side 14
(9) Lower ball joint bolt 62
(10) Front driveshaft lower arm bolts 105
(11) Shock absorber lower bolts 105
(12) Shock absorber rod nut 21
(13) Hub nut 280
(14) Steering box bolts 105
(15) Track rod end nut 37
(16) Wheel alignment lock nut 53
(17) Wheel bolts 105

30A-36
GENERAL INFORMATION
Front axle system: Adjustment
30A
I - ADJUSTMENT PREPARATION STAGE
aCheck the geometry (see 30A, General informa-
tion, Axle assemblies: Check, page 30A-23) .
II - ADJUSTMENT OPERATION
1 - Wheel alignment
aSet the wheels straight ahead.
aLock the steering wheel using a flywheel immobil-
iser.
aAdjust the wheel alignment by rotating the track rod
sleeves.
aLoosen the wheel alignment adjustment lock nut (1)
.
aTurn the track rod sleeve (2) to the required value.
aAfter adjustment, torque tighten the wheel align-
ment adjustment lock nuts (53 N.m).2 - Castor angle
aNot adjustable.
3 - Camber
aNot adjustable.
4 - Pivot
aNot adjustable. Equipment required
flywheel immobiliser
Tightening torquesm
wheel alignment adjust-
ment lock nuts53 N.m
121364

31A-1
FRONT AXLE COMPONENTS
Front brake pads: Removal - Refitting
EQ UIPMENT LEVEL EA0 or EQUIPMENT LEVEL EA1 or EQUIPMENT LEVEL EA3 or EQUIPMENT LEVEL EA5
or EQUIPMENT LEVEL EAG or EQUIPMENT LEVEL EZ2 or EQUIPMENT LEVEL EZ4
31A
When replacing brake pads, be sure to replace the
pads on the opposite side.
REMOVAL
I - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) .
aSwitch off the ignition without removing the key to
keep the steering column unlocked.
aRemove the front wheels (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the guide pin lower bolt (1) while holding
the nut (2) .aRotate the calliper upwards.
aRemove the pads (3) . Tightening torquesm
guide pin bolt34 N.m
119213
119215
119216

31A-8
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
EQ UIPMENT LEVEL EA0 or EQUIPMENT LEVEL EA1 or EQUIPMENT LEVEL EA3 or EQUIPMENT LEVEL EA5
or EQUIPMENT LEVEL EAG or EQUIPMENT LEVEL EZ2 or EQUIPMENT LEVEL EZ4
31A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) .
aFit the pedal press to the brake pedal to limit the
outflow of brake fluid.
aUnlock the steering column.
aRemove the front wheel on the side concerned (see
35A, Wheels and tyres, Wheel: Removal - Refit-
ting, page 35A-1) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnlock the brake hose (1) on the brake calliper.
aRemove the brake pads (see 31A, Front axle com-
ponents, Front brake pads: Removal - Refitting,
page 31A-1) . Equipment required
pedal press
Tightening torquesm
guide pin bolts34 N.m
brake hose17 N.m
Note:
The callipers supplied as spare par ts are pre-filled
with br ake fluid.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
119214
WARNING
In order not to damage the brake hose:
-do not tension the hose,
-do not twist the hose,
-check that there is no contact with the sur-
rounding components.

31A-12
FRONT AXLE COMPONENTS
Front brake calliper: Repair
31A
REPAIR
I - REPAIR PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aPosition the pedal press on the brake pedal to limit
the outflow of brake fluid.
aRemove:
-the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
-the front brake calliper (see 31A, Front axle com-
ponents, Front brake calliper: Removal - Refit-
ting, page 31A-8) .II - REPAIR OPERATION FOR PART CONCERNED
aRemove the piston using compressed air, making
sure to insert a wooden block between the calliper
and the piston to avoid damaging it. Any trace of im-
pact on the end panel will render the piston unfit for
use.
aRemove the dust seal.
aRemove the rectangular section seal from the calli-
per groove with a round edged spring blade (feeler
gauge).
aClean the parts using methylated spirit. Special tooling required
Fre. 1190-01Brake calliper piston return
tool.
Equipment required
pedal press
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see Front axle components: Precautions
for the repair) .
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
81546
81545
WARNING
The whole calliper must systematically be
replaced if there are any scratches in the calliper
bore.