torque RENAULT TWINGO RS 2009 2.G Transmission Owner's Manual

21B-19
SEQUENTIAL GEARBOX
Pump assembly: Removal - Refitting
D4F, and JH1
21B
aPosition the (Ms. 583) on the reservoir low pressure
return hose (1) .
aRemove the clip (2) from the reservoir return hose.
aDisconnect the reservoir low pressure return hose
(1) from the actuator module.
aRemove:
-the clutch stay high pressure supply pipe bracket
bolt (3) ,
-the actuator module high pressure supply pipe by
pressing on the unions (4) ,
-the clutch stay high pressure supply pipe by press-
ing on the unions (5) ,
-the pump assembly from the actuator module.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aFit:
-the clutch stay high pressure supply pipe,
-the actuator module high pressure supply pipe.
aFit the high pressure pipe unions, without tightening
them.aConnect the reservoir low pressure return hose to
the actuator module.
aRefit the reservoir return hose clip on the actuator
module.
aRemove the (Ms. 583) from the reservoir low pres-
sure return hose.
aClip the pump assembly supply connector onto the
electro-hydraulic unit connector mounting.
aConnect the pump assembly supply connector.
II - FINAL OPERATION
aRefit the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Refit-
ting, page 21B-11) .
aTorque tighten the high pressure pipe unions (14
N.m).
aRefit:
-the clutch stay high pressure supply pipe bracket
bolt,
-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 rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-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 sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aFill the electric pump assembly reservoir with oil
(see Sequential gearbox oil: Specifications)
(Technical Note 6012, 04A, Lubricants) to between
32 and 38 mm above the MIN mark.
122171
Note:
Prepare for oil to flow out of the electro-hydraulic
unit.
WARNING
After the accumulator has been fully filled (15
seconds after the ignition has been switched on):
the oil level is at the MINIMUM mark.

21B-21
SEQUENTIAL GEARBOX
Solenoid valves: Removal - Refitting
D4F, and JH1
21B
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).
aDetach from the petrol injection computer mounting:
-the cooling hose,
-the sequential gearbox computer wiring harness,
-the petrol injection computer wiring harness,
-the battery wiring harness.
aRemove:
-the petrol injection computer mounting nut (1) , Special tooling required
Mot. 1390Suppor t for removal - refitting
of engine - gearbox assembly
Equipment required
Diagnostic tool
Tightening torquesm
left-hand suspended
engine mounting bolts21 N.m
left-hand suspended
engine mounting rubber
pad bolts62 N.m
left-hand suspended
engine mounting rubber
pad nut105 N.m
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).
122323
122322

21B-25
SEQUENTIAL GEARBOX
Solenoid valves: Removal - Refitting
D4F, and JH1
21B
a
aRemove:
-the bolts (19) from engagement solenoid valve 2,
-engagement solenoid valve 2.
REFITTING
I - REFITTING PREPARATION OPERATION
aIt is essential to replace the engagement or clutch
solenoid valve seal.
II - REFITTING OPERATION FOR PART
CONCERNED
1 - Refitting engagement solenoid valve 1,
selection solenoid valve 3 and selection solenoid
valve 4
aRefit the affected solenoid valve, following the cor-
rect removal order for the solenoid valves:
-engagement solenoid valve 1 fitted with its new
seal,
-selection solenoid valve 3,
-selection solenoid valve 4,
-the clutch solenoid valve fitted with its new seal.2 - Refitting engagement solenoid valve 2
aRefit:
-engagement solenoid valve 2 fitted with its new
seal,
-engagement solenoid valve 2 bolts.
aConnect the connectors:
-to engagement solenoid valve 2,
-to the solenoid valve unit pressure sensor.
III - FINAL OPERATION
1 - Refitting engagement solenoid valve 1,
selection solenoid valve 3 and selection solenoid
valve 4
aFit the electro-hydraulic unit connector mounting.
aRefit the electro-hydraulic unit connector mounting
bolts.
aClip the pump assembly supply connector onto the
electro-hydraulic unit connector mounting.
aConnect the pump assembly supply connector.
aRefit:
-the sequential gearbox lifting eye on the sequential
gearbox,
-the sequential gearbox lifting eye nut,
-the breather pipe on the sequential gearbox.
aAttach the breather pipe:
-to the cooling hose,
-to the sequential gearbox lifting eye.
2 - Refitting engagement solenoid valve 2
aFit the left-hand suspended engine mounting to the
body.
aFit the left-hand suspended engine mounting bolts
without tightening them.
aTorque tighten the left-hand suspended engine
mounting bolts (21 N.m).
aRaise the sequential gearbox to its original position.
aFit the left-hand suspended engine mounting rubber
pad.
aFit the left-hand suspended engine mounting rubber
pad bolts without tightening them.
aTorque tighten the left-hand suspended engine
mounting rubber pad bolts ( 62 N.m).
122319
Note:
Prepare for oil to flow out of the electro-hydraulic
unit.

21B-26
SEQUENTIAL GEARBOX
Solenoid valves: Removal - Refitting
D4F, and JH1
21B
aFit the left-hand suspended engine mounting rubber
pad nut without tightening it.
aTorque tighten the left-hand suspended engine
mounting rubber pad nut (105 N.m ).
aRefit:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres).
3 - Refitting all solenoid valves
aFit:
-the petrol injection computer support,
-the engine wiring harness on the petrol injection
computer mounting.
aRefit:
-the petrol injection computer mounting bolts,
-the engine wiring harness nut on the petrol injec-
tion computer mounting,
-the petrol injection computer mounting nut.
aClip onto the petrol injection computer mounting:
-the battery wiring harness,
-the petrol injection computer wiring harness,
-the sequential gearbox computer wiring harness,
-the cooling hose.
aRefit:
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery).aFill the electric pump assembly reservoir with oil
(see Sequential gearbox oil: Specifications)
(Technical Note 6012, 04A, Lubricants) to between
32 and 38 mm above the MIN mark.
aCarry out the necessary operations using the Diag-
nostic tool (see Fault finding - Replacement of
components) (MR 413, 21B, Sequential gearbox). WARNING
After the accumulator has been fully filled (15
seconds after the ignition has been switched on):
the oil level is at the MINIMUM mark.

21B-28
SEQUENTIAL GEARBOX
Actuator module: 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 front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the front wheel arch liners (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) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (MR 411, 31A, Front axle
components).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the supply connector from the pump as-
sembly pump.
aDetach the pump assembly pump supply connector
from the electro-hydraulic unit connector mounting. Special tooling required
Ms. 583Pipe clamps .
Equipment required
Diagnostic tool
Tightening torquesm
high pressure pipe
unions14 N.m
IMPORTANT
Before carrying out any operation on the sequential
system, discharge the accumulator using the diag-
nostic 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).

21B-29
SEQUENTIAL GEARBOX
Actuator module: Removal - Refitting
D4F, and JH1
21B
aPosition the (Ms. 583) on the reservoir low pressure
return hose (1) .
aRemove the clip (2) from the reservoir return hose.
aDisconnect the reservoir low pressure return hose
(1) from the actuator module.
aRemove:
-the clutch stay high pressure supply pipe bracket
bolt (3) ,
-the actuator module high pressure supply pipe by
pressing on the unions (4) ,
-the clutch stay high pressure supply pipe by press-
ing on the unions (5) ,
-the actuator module from the pump assembly.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aFit:
-the clutch stay high pressure supply pipe,
-the actuator module high pressure supply pipe.
aFit the high pressure pipe unions, without tightening
them.
aConnect the reservoir low pressure return hose to
the actuator module.
aRefit the reservoir return hose clip on the actuator
module.
aRemove the (Ms. 583) from the reservoir low pres-
sure return hose.
aClip the pump assembly supply connector onto the
electro-hydraulic unit connector mounting.
aConnect the pump assembly supply connector.
II - FINAL OPERATION
aRefit the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Refit-
ting, page 21B-11) .
aTorque tighten the high pressure pipe unions (14
N.m).
aRefit:
-the clutch stay high pressure supply pipe bracket
bolt,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (MR 411, 31A, Front axle
components),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
122171
Note:
Prepare for oil to flow out of the electro-hydraulic
unit.
Note:
Prepare for oil to flow out of the electro-hydraulic
unit.

21B-38
SEQUENTIAL GEARBOX
Sequential gearbox engine speed sensor: Removal - Refitting
D4F, and JH1
21B
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) .aRemove:
-the left-hand suspended engine mounting shaft
bolts (1) ,
-the left-hand suspended engine mounting shaft.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the sequential gearbox engine speed sensor bolt
(2) ,
-the sequential gearbox engine speed sensor. Tightening torquesm
left-hand suspended
engine mounting shaft
bolts62 Nm
122161
122160

21B-39
SEQUENTIAL GEARBOX
Sequential gearbox engine speed sensor: Removal - Refitting
D4F, and JH1
21B
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the sequential gearbox engine speed sensor,
-the sequential gearbox engine speed sensor bolt.
II - FINAL OPERATION
aFit the left-hand suspended engine mounting shaft
onto the sequential gearbox.
aFit the left-hand suspended engine mounting shaft
bolts without tightening them.
aTorque tighten the left-hand suspended engine
mounting shaft bolts (62 Nm).
aRefit:
-the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Re-
fitting, page 21B-11) ,
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery).

21B-40
SEQUENTIAL GEARBOX
Sequential gearbox: Removal - Refitting
D4F, and JH1
21B
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 air filter unit (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the catalytic converter (see Catalytic converter:
Removal - Refitting) ,
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection).
aDrain:
-the cooling system (see Cooling system: Drain-
ing - Refilling) (MR 411, 19A, Cooling),
-the sequential gearbox (see 21A, Manual gear-
box, Manual gearbox oils: Draining - Filling,
page 21A-2) .
aDrain the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (MR 411, 62A, Air conditioning).
aRemove:
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (MR
411, 10A, Engine and peripherals),
-the hub-carrier - driveshaft assembly (see ) (MR
411, 31A, Front axle components),
-the starter (see Starter: Removal - Refitting) (MR
411, 16A, Starting - Charging),
-the crankshaft position sensor (see Crankshaft
position sensor: Removal - Refitting) (MR 411,
17B, Petrol injection). Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Equipment required
workshop hoist
load balancer
roller-type stud removal tool
Tightening torquesm
sequential gearbox
studs7 Nm
sequential gearbox bolts44 Nm
sequential gearbox nuts44 Nm
flywheel protection plate
bolts (18)44 Nm
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)
.
AIR CONDITIONING or CLIMATE CONTROL

21B-45
SEQUENTIAL GEARBOX
Sequential gearbox: Removal - Refitting
D4F, and JH1
21B
If replacing the sequential gearbox
aRefit:
-the sequential gearbox engine speed sensor (see
21B, Sequential gearbox, Sequential gearbox
engine speed sensor: Removal - Refitting, page
21B-38) ,
-the reverse gear switch (17) .
II - REFITTING OPERATION FOR PART
CONCERNED
aFit the sequential gearbox to the engine.
aFit the sequential gearbox studs without tightening
them.
aTorque tighten the sequential gearbox studs (7
Nm) using a roller-type stud removal tool.
aFit without tightening:
-the sequential gearbox bolts,
-the sequential gearbox nuts.
aTighten to torque:
-the sequential gearbox bolts (44 Nm),
-the sequential gearbox nuts (44 Nm).aRefit:
-the flywheel protection plate,
-the flywheel protection plate bolt.
aFit the flywheel protection plate bolts (18) without
tightening them.
aTorque tighten the flywheel protection plate bolts
(18) (44 Nm).
III - FINAL OPERATION
aAttach the engine wiring harness neck to the se-
quential gearbox.
aRefit the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Refit-
ting, page 21B-11) .
aFit the « engine - sequential gearbox » assembly to
the front axle sub-frame using a workshop hoist
and a load balancer in its original position.
aRefit the « cooling radiator - cooling radiator hose »
assembly to the front axle sub-frame.
122163
122158
STANDARD HEATING