drain bolt RENAULT TWINGO 2009 2.G Transmission Workshop Manual

20A-6
CLUTCH
Pressure plate - Disc: Removal - Refitting
K4M
20A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray bolts,
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery)
-the air filter box (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).aRemove:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) .
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the manual gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the (Mot. 1677) (1) .
aRemove:
-the clutch pressure plate bolts (2) ,
-the clutch pressure plate,
-the clutch plate. Special tooling required
Mot. 1677Flywheel locking tool.
Emb. 1780Set of clutch plate centr ing
mandrels.
Tightening torquesm
clutch pressure plate
bolts23 N.m
132329

21A-11
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
101391
(60) Mechanism housing
(61) Filler plug
(62) Spacer
(63) Oil channel
(64) Breather pipe
(65) Reverse gear sensor
(66) O-r ing
(67) Fifth gear housing
(68) Gearbox bell housing bolt
(69) Fifth gear housing bolt
101392
(70) Clutch housing
(71) Drain plug
(72) Magnet
(73) Hydraulic clutch release bearing
(74) Hydraulic clutch release bear-
ing bolt

21A-24
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and JH3 or JR5
21A
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).
-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).
aDisconnect the engine management computer con-
nectors.
aRemove:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aRemove the engine management computer mount-
ing.
aRemove the engine management computer wiring
harness nut from the engine management computer
mounting.
aRemove the engine management computer wiring
harness.
aRemove the engine management computer mount-
ing fitted with the engine management computer.aUnclip:
-the clutch hydraulic control pipe on the gearbox (1)
,
-the union (2) on the hydraulic tappet slave cylinder,
-the gearbox breather.
aRemove:
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection).
aDrain the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (31A, Front axle com-
ponents),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting). Special tooling required
Mot. 1453Engine anchorage support
with m ultiple adjustments and
retaining str aps.
Equipment required
component jack
Tightening torquesm
lower gearbox bolts44 N.m
gearbox nuts and bolts44 N.m
gearbox upper bolts44 N.m
121410

21A-26
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and JH3 or JR5
21A
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the gearbox using a component jack,
-the gearbox stud nuts,
-the gearbox lower bolts.
aTorque tighten:
-the lower gearbox bolts (44 N.m),
-the gearbox nuts and bolts (44 N.m).
aRefit the upper gearbox bolts.
aTorque tighten the gearbox upper bolts (44 N.m).
aRefit the earth strap bolt on the gearbox.
aConnect:
-the reverse gear switch connector,
-the speed and position sensor connector.
aClip the gearbox controls into place.
II - FINAL OPERATION
aRefit:
-the subframe (see Front axle subframe: Removal
- Refitting) (31A, Front axle components),
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting).
aRemove the tool (Mot. 1453).
aRefit:
-the upstream strut of the catalytic converter by slid-
ing it upwards,
-the catalytic converter upstream strut bolt on the
catalytic converter.
aTighten the bolt and nut on the upstream strut of the
catalytic converter on the gearbox.
aRefit:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (31A, Front axle com-
ponents),
-the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging),-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aClip:
-the union onto the hydraulic tappet slave cylinder,
-the hydraulic clutch control pipe,
-the gearbox breather.
aBleed the clutch (see Clutch circuit: Bleed) (37A,
Mechanical component controls).
aRefit the engine management computer mounting
fitted with the engine management computer.
aFit the engine management computer wiring har-
ness.
aRefit the engine management computer wiring har-
ness nut on the engine management computer
mounting.
aFit the engine management computer mounting.
aRefit:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aConnect the engine management computer connec-
tors.
aRefit:
-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),
aFill up the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRefit:
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the battery (see Battery: Removal - Refitting)
(80A, Battery).

21A-27
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
D4F, and JB1 – D7F, and JB1
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery).
aRemove the air filter unit (see Air filter unit: Re-
moval - Refitting) (MR 411, 12A, Fuel mixture).
aRemove:
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 412, 56A, Exterior
equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (MR 412, 56A, Exterior equipment).aDisconnect the engine management computer con-
nectors.
aRemove:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aRemove the engine management computer mount-
ing.
aRemove the engine management computer wiring
harness nut from the engine management computer
mounting.
aRemove the engine management computer wiring
harness.
aRemove the engine management computer mount-
ing fitted with the engine management computer.
aUnclip:
-the clutch cable,
-the gearbox breather.
aRemove:
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection).
aDrain the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (MR 411, 31A, Front
axle components),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the starter (see Starter: Removal - Refitting) (MR
411, 16A, Starting - Charging). Special tooling required
Mot. 1453Engine anchorage support
with m ultiple adjustments and
retaining str aps.
Equipment required
component jack
Tightening torquesm
gearbox mountings44 Nm
D4F

21A-29
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
D4F, and JB1 – D7F, and JB1
21A
aRefit the engine management computer mounting
fitted with the engine management computer.
aFit the engine management computer wiring har-
ness.
aRefit the engine management computer wiring har-
ness nut on the engine management computer
mounting.
aFit the engine management computer mounting.
aRefit:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aConnect the engine management computer connec-
tors.
aRefit:
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (MR 412, 56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 412, 56A, Exterior
equipment).
aRefit the air filter box (see Air filter unit: Removal -
Refitting) (MR 411, 12A, Fuel mixture).
aFill up the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRefit:
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery). D4F

21A-30
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).aRemove:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) ,
-the differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-38) (21A, Manual gearbox),
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the “engine - gearbox” assembly from
theusing a workshop hoist.
aDisconnect the TDC sensor connector (1) . Equipment required
workshop hoist
Tightening torquesm
manual gearbox nuts
and bolts44 N.m
earth strap bolt on the
gearbox44 N.m
support bolts for the
suspended engine
mounting on the gear-
box62 N.m
132319

21A-33
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
aFit the engine wiring.
aRefit:
-the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging),
-the bolts of the engine wiring channel,
-the earth strap bolt on the gearbox.
aTorque tighten the earth strap bolt on the gearbox
(44 N.m).
aConnect the reverse gear switch connector.
aClip on the reverse gear switch.
aRefit the suspended engine mounting support on the
gearbox.
aTorque tighten the support bolts for the suspend-
ed engine mounting on the gearbox (62 N.m).
aConnect the TDC sensor connector.
aRefit the engine - gearbox assembly on the.
III - FINAL OPERATION
aRefit:
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-38) (21A, Manual gearbox),
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) .
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aRefill:
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).
aRefit the engine undertray.

21B-3
SEQUENTIAL GEARBOX
Sequential gearbox oil: Draining - Filling
JH1
21B
Oil capacity
DRAINING
I - DRAINING PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray bolts,
-the engine undertray.
II - DRAINING OPERATION
aFit a oil recovery tray under the gearbox.aRemove:
-the gearbox drain plug (1) using the tool (Mot.
1018),
-the drain plug seal.
aLet the oil run into the oil recovery tray.
FILLING
I - FILLING PREPARATION OPERATION
aAlways replace the manual gearbox drain plug seal. Special tooling required
Mot. 10188 mm square engine drain
plug spanner.
Equipment required
oil recovery tray
Tightening torquesm
drain plug25 N.m
Gearbox type Oil capacity (in litres)
JH1 2.8
JA32.8
JA52.5
18749

21B-9
SEQUENTIAL GEARBOX
Pump assembly reservoir: Removal - Refitting
D4F, and JH1
21B
The electro-hydraulic unit comprises the pump assem-
bly and the actuator module.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection).
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres),-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Re-
fitting, page 21B-11) ,
aPosition the (Ms. 583)
aSeparate
-the pump assembly from the electro-hydraulic unit
(see 21B, Sequential gearbox, Pump assembly:
Removal - Refitting, page 21B-18) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the (Ms. 583) (1) from the low pressure
hose (2) .
aDrain the pump assembly reservoir.
aRemove:
-the bolts (3) from the pump assembly reservoir,
-the electric pump unit tank.
aIn the event of replacement, remove:
-the clip (4) from the low pressure hose (2) ,
-the low pressure hose (2) . Special tooling required
Ms. 583Pipe clamps .
Equipment required
Diagnostic tool
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 21B, Sequential gearbox, Sequential
gearbox: Precautions for the repair, page 21B-1)
.
Note:
To discharge the accumulator and deactivate the
pump assembly pump, (see Fault finding -
Replacement of components) (MR 413, 21B,
Sequential gearbox).
122173