RENAULT TWINGO RS 2009 2.G Panelwork Workshop Manual

42A-12
FRONT UPPER STRUCTURE
Front upper cross member: General description
42A
DESIGN OF THE STRUCTURAL COMPONENT
The special feature of this part it that it concurrently
serves two functions:
-front upper cross member,
-front headlight mounting. WARNING
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, 40A, General Information.
121036

42A-13
FRONT UPPER STRUCTURE
Front upper cross member: Removal - Refitting
42A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the front bumper ( (see Front bumper: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip the wiring harness.
aRemove the bonnet opening cable.
aRemove the bolt (1) from the coolant bottle.
aUnclip the coolant bottle.
aRemove:
-the bolt (2) from the cooling radiator deflector,
-the front upper cross member bolts (3) .
aUndo the bolts (4) .
aRemove the front upper cross member.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the front upper cross member,
-the bolts (3) ,
-the bolt (2) on the cooling radiator deflector.
aTighten the bolts (4) .
aClip on the coolant bottle.
aRefit the bolt (1) on the coolant bottle.
aPosition the bonnet opening release cable.
aClip on the wiring harness.
II - FINAL OPERATION.
aRefit:
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the front bumper ( (see Front bumper: Removal -
Refitting) ).
121036
Note:
The bolts (4) can be accessed between the front
end lower cross member and the cooling radia-
tor.

42A-14
FRONT UPPER STRUCTURE
Scuttle side panel: General description
42A
I - DESIGN OF THE STRUCTURAL COMPONENT
The special feature of this part it that it concurrently
serves two functions:
-scuttle side panel,
-A-pillar lining.II - AREA TO BE CUT FOR PARTIAL
REPLACEMENT
Cutting line (2) shows the area in which it is possible to
make a cut.
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). 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.
109831
110561
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).

42A-15
FRONT UPPER STRUCTURE
Scuttle side panel: General description
42A
Line (6) on the diagram shows the partial replacement
and an EGW butt weld.
Depending on the exact position of the cut, a weld
made by joggling connected with plug welds at regular
intervals may also be used.
110562

42A-16
FRONT UPPER STRUCTURE
Scuttle side panel: Description
42A
To replace this part, also order the front wing mounting
bracket (A) .
The options for replacing this part are as follows:
-partial replacement of the front end section,
-partial frontal replacement
I - COMPOSITION OF THE SPARE PARTII - PART IN POSITION
1 - Partial replacement of the front end section
2 - Partial front replacement
121056
120980
No. Description Type Thic-
kness
(mm)
(1) A-pillar lining Mild
steel0.9
(2) Dashboard
mounting unitMild
steel1.5
120983
120982

42A-17
FRONT UPPER STRUCTURE
Scuttle side panel: Description
42A
This cut gives access to the front wheel arch.
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
120981
IMPORTANT
For welded connections in three thicknesses, the
spot welds on the part replaced should be made in
the same place as for the original joint to retain its
mechanical proper ties.
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.

42A-18
FRONT UPPER STRUCTURE
Upper reinforcement of scuttle side panel: General description42A
DESIGN OF THE STRUCTURAL COMPONENT
This type of part secures the bonnet hinge mounting
and the front wing upper mounting support.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.
121053

42A-19
FRONT UPPER STRUCTURE
Upper reinforcement of scuttle side panel: Description42A
There is only one way of replacing this part:
-complete replacement.
I - COMPOSITION OF THE SPARE PARTII - PART IN POSITION
Complete replacement
121053
120984
No. Description Type Thic-
kness
(mm)
(1) A-pillar lining
reinforcementHLE0.9
(2) A-pillar lining
reinforcement
rear stiffenerHEL1.3
120985
IMPORTANT
For welded connections in three thicknesses, the
spot welds on the par t replaced should be made in
the same place as for the original joint to retain its
mechanical proper ties.
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.

42A-20
FRONT UPPER STRUCTURE
Upper reinforcement of scuttle side panel: Description42A
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.

42A-21
FRONT UPPER STRUCTURE
Front wheel arch: General description
42A
DESIGN OF THE STRUCTURAL COMPONENT
Left side
This part consists of a wheel arch front section and a
windscreen wiper mechanism mounting.Right-hand side
This part consists of a wheel arch front section and an
engine mounting. 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.
120930
120929