RENAULT TWINGO 2009 2.G Panelwork Service Manual

41A-2
FRONT LOWER STRUCTURE
Front end lower cross member: Description
41A
There is only one way of replacing this part:
-complete replacement.
I - COMPOSITION OF THE SPARE PARTII - PART FITTED
120675
Note:
The repair bench does not have to be used, on con-
dition that the side members have not been affected
by the impact.
120676
No. Description Type Thic-
kness
(mm)
(1) Front cross mem-
ber closure panelHLE1.5
(2) Tow hitch socket Mild
steel-
(3) Front tow hitch
supportMild
steel3
(4) Front end cross
memberHLE1.5
120677
WARNING
If the spot welds cannot be made as they were ori-
ginally using an electrical spot welding machine,
they should be replaced with plug welds after holes
have been drilled in the first panel. No. Description Type Thic-
kness
(mm)

41A-3
FRONT LOWER STRUCTURE
Front end lower cross member: Description
41A
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
121245
IMPORTANT
To avoid damaging the vehicle's electric and elec-
tronic components, the battery and the earths of
any wiring harness near the weld area must be dis-
connected.
The earth of the welding machine must be placed
as close as possible to the weld area.

41A-4
FRONT LOWER STRUCTURE
Radiator mounting cross member: General description41A
DESIGN OF THE STRUCTURAL COMPONENT
This steel part, which bolts onto the end of the front
axle subframe, combines two functions:
-absorption of front impact forces,
-radiator support cross member. Note:
The information contained in the following descri-
bes the general repair procedure for all vehicles
having the same design for this part.
Before reading this general information, check that
there are no special notes associated with this vehi-
cle. These special notes will be specified if applica-
ble in other parts of this subsection dealing with the
par t.
Note:
For a detailed description of a particular connec-
tion, see MR 400.
121040

41A-5
FRONT LOWER STRUCTURE
Radiator mounting cross member: Removal - Refitting41A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the front bumper ( (see Front bumper: Re-
moval - Refitting) ).
aAttach the radiator upper section.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the bolts (1) ,
-the radiator mounting cross member.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the radiator mounting cross member,
-the bolts (1) .
aTorque tighten the radiator mounting cross mem-
ber bolts (44 Nm).II - FINAL OPERATION.
aDetach the radiator upper section.
aRefit the front bumper ( (see Front bumper: Remo-
val - Refitting) ). Tightening torquesm
radiator mounting cross
member bolts44 Nm
121040

41A-6
FRONT LOWER STRUCTURE
Front side member: General description
41A
I - DESIGN OF THE STRUCTURAL COMPONENT
This is a basic part; its only function is that of front side
member, front section.II - AREA TO BE CUT FOR PARTIAL
REPLACEMENT
Cut 1:
This line marks the place in which it is possible to make
a partial replacement.
This operation allows you to access the inside of the
hollow section of the structural element to straighten it.
In this case, the side member weld line must be stag-
gered from that of its closure panel.
III - ASSEMBLY METHOD FOR A PARTIAL
REPLACEMENT
Only the connections which are specific to the partial
replacement by cutting are indicated.
If there are other issues regarding access to mating fa-
ces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400). IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometr y of the axle assemblies.
Note:
The information contained in the following descri-
bes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associa-
ted with the vehicle. These special notes are speci-
fied if necessary in other par ts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connec-
tion, see MR 400.
110548
110549
Note:
For the partial replacement of parts constituting a
single structural component, it is essential to stag-
ger the welds of each of the components.
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).

41A-7
FRONT LOWER STRUCTURE
Front side member: General description
41A
Line (3) on the drawing shows a butt weld by conti-
nuous EGW welding.
110550

41A-8
FRONT LOWER STRUCTURE
Front side member, front section: Description
41A
The options for replacing this part are as follows:
-partial replacement,
-complete replacement.
I - COMPOSITION OF THE SPARE PART
Left sideRight-hand side
120643
IMPORTANT
The straightening bench must be used.
120645
No. Description Type Thic-
kness
(mm)
(1) Front side mem-
ber front sectionHLE1.5
(2) Front mounting of
front subframeHLE1.2
(3) Front side mem-
ber inner stiffenerMild
steel1.2
120644
No. Description Type Thic-
kness
(mm)
(4) Engine mounting
reinforcementMild
steel1.5
(5) Engine mounting
stiffener closure
panel componentMild
steel1
(6) Front side mem-
ber front sectionHLE1.5
(7) Front mounting of
front subframeHLE1.2

41A-9
FRONT LOWER STRUCTURE
Front side member, front section: Description
41A
II - PART FITTED
1 - Partial replacement
Left side
Right-hand side
2 - Complete replacement
Left sideRight-hand side
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
120671
120672
120673
120674
WARNING
If the spot welds cannot be made as they were ori-
ginally using an electrical spot welding machine,
they should be replaced with plug welds after holes
have been drilled in the first panel.
121245

41A-10
FRONT LOWER STRUCTURE
Front side member, front section: Description
41A
IMPORTANT
To avoid damaging the vehicle's electric and elec-
tronic components, the battery and the earths of
any wiring harness near the weld area must be dis-
connected.
The earth of the welding machine must be placed
as close as possible to the weld area.

41A-11
FRONT LOWER STRUCTURE
Front side member closure panel, front section: General description41A
I - DESIGN OF THE STRUCTURAL COMPONENT
This is a basic part; its only function is that of front side
member closure panel, front section.
II - AREA TO BE CUT FOR PARTIAL
REPLACEMENT
For removal of the side member (see Front side mem-
ber: Description) .Cut 1:
This line shows the centre of the area in which it is pos-
sible to carry out a partial replacement.
This operation allows you to access the inside of the
hollow section of the structural component to straigh-
ten it.
III - ASSEMBLY INSTRUCTIONS FOR A PARTIAL
REPLACEMENT
In this case, the side member weld line must be stag-
gered from that of its closure panel.
Only the connections which are specific to the partial
replacement by cutting are indicated.
If there are other issues regarding access to mating fa-
ces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400). IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometr y of the axle assemblies.
Note:
The information contained in the following descri-
bes the general repair procedure for all vehicles
having the same design for this part.
Before reading the following general information,
make sure that there are no special notes associa-
ted with the vehicle. These special notes are speci-
fied if necessary in other par ts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connec-
tion, see MR 400.
109550
Note:
For the partial replacement of parts constituting a
single structural component, it is essential to stag-
ger the welds of each of the components.
110553
Note:
For the partial replacement of parts constituting a
single structural component, it is essential to stag-
ger the welds of each of the components.
WARNING
If the mating faces of the parts to be welded are not
accessible, make EGW plug welds to replace the
original resistance welds (see MR 400).