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

TWINGO - Chapitre 3
Contents
Pages
TWINGO - Chapitre 3ContentsPages
30A GENERAL INFORMATION
Brake circuit: Operating
diagram 30A-1
Brake circuit: Precautions for
the repair 30A-2
Braking circuit: Bleed 30A-4
Brake circuit: Tightening
torque 30A-6
Rigid brake pipe: Repair 30A-13
Brake fluid: Specifications 30A-18
Brake: Specifications 30A-19
Steering: Tightening torque 30A-20
Axle assemblies: Check 30A-23
Underbody heights:
Adjustment value 30A-24
Front axle system:
Tightening torque 30A-27
Front axle assembly:
Adjustment values 30A-31
Front axle system:
Adjustment 30A-36
Rear axle system: Tightening
torque 30A-37
Rear axle assembly:
Adjustment values 30A-3831A FRONT AXLE COMPONENTS
Front brake pads: Removal -
Refitting 31A-1
Front brake hose: Removal -
Refitting 31A-6
Front brake calliper: Removal
- Refitting 31A-8
Front brake calliper: Repair 31A-12
Front brake calliper
mounting: Removal -
Refitting 31A-14
Front brake disc protector:
Removal - Refitting 31A-18
Front brake disc: Removal -
Refitting 31A-19
Front brake disc: Description 31A-22
Front driveshaft hub carrier:
Removal - Refitting 31A-23
Front hub carrier bearing:
Removal - Refitting 31A-26
Front shock absorber and
spring: Removal - Refitting 31A-29
Front driveshaft lower arm:
Removal - Refitting 31A-33
Front driveshaft lower arm
ball joint: Removal - Refitting 31A-40
Front axle subframe:
Removal - Refitting 31A-43

Contents
Radiator mounting cross
member: Removal - Refitting 31A-51
Front anti-roll bar: Removal -
Refitting 31A-52
33A REAR AXLE COMPONENTS
Rear brake pads: Removal -
Refitting 33A-1
Rear brake hose: Removal -
Refitting 33A-4
Rear brake calliper: Removal
- Refitting 33A-7
Rear brake calliper
mounting: Removal -
Refitting 33A-9
Rear brake disc: Removal -
Refitting 33A-11
Rear brake disc: Description 33A-13
Rear brake lining: Removal -
Refitting 33A-14
Rear brake cylinder:
Removal - Refitting 33A-17
Rear brake drum: Removal -
Refitting 33A-19
Rear brake drum:
Description 33A-21
Rigid brake pipe: Removal -
Refitting 33A-22
Shock absorber: Removal -
Refitting 33A-24
Rear suspension spring:
Removal - Refitting 33A-28
Rear drum bear ing: Removal
- Refitting 33A-30
Rear stub axle carr ier:
Removal - Refitting 33A-32
Complete rear axle system:
Removal - Refitting 33A-37 31A FRONT AXLE COMPONENTS
35A WHEELS AND TYRES
Wheel: Removal - Refitting 35A-1
Wheel: Balancing 35A-4
Tyres: Identification 35A-7
Tyres: Removal - Refi tting 35A-8
Tyre pressure: Identification 35A-10
Wheel r im: Identifi cation 35A-11
36A STEERING ASSEMBLY
Steering box: Removal -
Refitting 36A-1
Track rod: Removal -
Refitting 36A-2
Axial ball joint linkage:
Removal - Refitting 36A-4
Steering column: List and
location of components 36A-6
Steering column: Removal -
Refitting 36A-7
Steering box gaiter: Removal
- Refitting 36A-16
Bulkhead seal: Removal -
Refitting 36A-17
Intermediate shaft: Removal
- Refitting 36A-18
Steering column adjustment
handle: Removal - Refitting 36A-21
Steering wheel: Removal -
Refitting 36A-23
36B POWER ASSISTED STEERING
Power-assisted steering
computer: Removal -
Refitting 36B-1

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-1
GENERAL INFORMATION
Brake circuit: Operating diagram
30A
« X » braking system with ABS
3877
IMPORTANT
This is a diagram of the general principle, do not
use it as a reference for take-off points or circuit
allocation. When replacing components in a vehi-
cle's braking circuit, always mark the pipes before
removing them.

30A-2
GENERAL INFORMATION
Brake circuit: Precautions for the repair
30A
I - SAFETY
1 - Advice to be followed before any operation
For an operation requiring the use of a lift, follow the
safety advice (see Vehicle: Towing and lifting) (02A,
Lifting equipment).
The brake regulation circuit must be free of all hydrau-
lic and electrical faults.
In case of incorrect handling, the brake fluid can cause
serious injury and damage. Follow the manufacturer's
instructions for brake fluid.
To prevent dust from entering the master cylinder res-
ervoir and the brake circuit, the plug must be removed
just before filling and closed immediately afterwards,
2 - Instructions to be followed during the operation
Do not press on the brake pedal during work on the
brake system.
If, during work on the brake system, any damage on
any part is observed, it must be repaired before driving
the vehicle again.
Brake fluid is highly corrosive. Ensure any brake fluid
spilt on parts of the vehicle is cleaned off.
Use brake fluids that comply with the Renault standard
(see Vehicle: Parts and consumables for the repair)
.
Check the brake fluid levels in the braking circuit and
the bleeding device.
Check that the pressure of the bleeding device is be-
tween 1.5 bar and 2 bar.
II - CLEANLINESS
1 - Advice to be followed before any operation
Protect any bodywork components that risk being dam-
aged by brake fluid with a cover.
2 - Instructions to be followed during the operation
Fit blanking plugs recommended for the Siemens K9K
injection system at the end of each pipe and in all the
openings of the disconnected components of the brake
circuit.
Clean around the braking system with BRAKE
CLEANER (see Vehicle: Parts and consumables
for the repair) (04B, Consumables - Products).Do not allow friction materials to come into contact with
grease, oil or other lubricants and cleaning products
which are mineral oil based.
III - GENERAL RECOMMENDATIONS
When replacing brake pads, always replace the pads
on the other side as well.
When replacing a disc, always replace the disc on the
opposite side.
When replacing brake discs, you must replace the
brake pads.
Always replace the rigid brake pipe clips.
Reminder:
-The pipes between the master cylinder, callipers and
the hydraulic assembly are connected using threaded
unions with a metric thread.
-Therefore, only parts specified in the Parts Catalogue
for this vehicle should be used. WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
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 surrounding
components, regardless of the position of the
wheels.
IMPORTANT
To avoid any accident, br ing the pistons, brake pads
and brake discs into contact by depressing the
brake pad several times.

30A-3
GENERAL INFORMATION
Brake circuit: Precautions for the repair
30A
Parts identification:
-shape of steel or copper pipe end piece (A),
-shape of connecting points on components (B),
-shape of unions (C): 11 mm hexagonal.
Precautions to be taken before and during the brake
circuit bleeding operation:
-use brake fluid which conforms to the Renault stan-
dard (see Vehicle: Parts and consumables for the
repair) (04B, Consumables - Products),
-check the brake fluid levels in the brake circuit and the
bleeding device,
-the braking regulation circuit must be free from all hy-
draulic and electrical faults,
-check that the pressure of the bleeding device is be-
tween 1.5 bars and 2 bars.
78491

30A-4
GENERAL INFORMATION
Braking circuit: Bleed
30A
This procedure must be applied after one of the fol-
lowing components has been removed or replaced:
-the master cylinder,
-the brake fluid,
-the hydraulic unit,
-a rigid pipe,
-a hose,
-the reservoir,
-a calliper.aUse locally produced containers to collect the used
brake fluid.
Front and rear callipers:
-2 washer fluid containers (1) (1 litre),
-4 mm diameter transparent pipes (2) ,
-4 pipettes (3) ,
-2 T-unions (4) .
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aSwitch off the vehicle ignition. Equipment required
pedal press
brake circuit bleeding device
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 30A, General information, Brake cir-
cuit: Precautions for the repair, page 30A-2) .
WARNING
Switch off the vehicle ignition so as not to activate
the hydraulic unit solenoid valves when bleeding the
brake circuit.
WARNING
The level must be between the « MIN » and
« MAX » markings on the reservoir.
115993
Note:
The new hydraulic unit is pre-filled.
When working on one of the following compo-
nents , position a pedal press to limit the outflow
of brake fluid and prevent any air from entering
the master cylinder and the circuits downstream
of the master cylinder:
-hydraulic unit,
-pipes between the hydraulic unit and brake cal-
lipers,
-brake hoses,
-brake calliper.
Remove the pedal press before carrying out the
braking system bleeding procedure.

30A-5
GENERAL INFORMATION
Braking circuit: Bleed
30A
aConnect the brake circuit bleeding device (after
having received Renault approval) to the master cyl-
inder reservoir (see the instructions for the equip-
ment).
aPressurise the brake circuit.
aAdjust the pressure to between 1.5 bar < P < 2 bar
for 3 minutes to stabilise it in the braking circuit.
aClose the circuit between the bleed screw and brake
fluid reservoir without dumping the pressure.
aFit the bleed containers to the four bleed screws of
the callipers.
aUndo the calliper bleed screws:
-front left-hand,
-front right-hand,
-rear left-hand,
-rear right-hand.
aOpen the circuit between the bleed screw and brake
fluid reservoir and allow the liquid to run until all the
air bubbles have been released.
aTighten the bleed screws in the following order:
-front left-hand,
-front right-hand,
-rear left-hand,
-rear right-hand.
aUndo the calliper bleed screw:
-front left-hand,
-allow the fluid to run until all the air bubbles have
been released,
-tighten the bleed screw on the calliper.
aCarry out the previous operation on the callipers:
-front right-hand,
-rear left-hand,
-rear right-hand.
aClose the bleed screw to dump the pressure in the
brake circuit.aRemove the brake circuit bleeding device from
the master cylinder reservoir.
aCheck pedal travel and resistance. If it is not correct,
finish bleeding the brake circuit with the help of a se-
cond operator. Start the bleed operation by bleeding
the calliper that is the furthest away from the master
cylinder:
-hold down the brake pedal,
-open the circuit bleed screw to release the air from
the brake circuit,
-close the circuit bleed screw,
-release the brake pedal.
aTop up the brake fluid level in the reservoir, if neces-
sary. Check the sealing of the front and rear bleed
screws and ensure that the sealing covers are in
place (see 30A, General information, Brake cir-
cuit: Tightening torque, page 30A-6) .
aDuring a road test, trigger braking regulation to con-
firm that the brake pedal travel is correct.
aClean off any traces of brake fluid on the vehicle us-
ing BRAKE CLEANING PRODUCT (see Vehicle:
Parts and consumables for the repair) Note:
The circuit between the bleed screw and brake
fluid reservoir is closed in different ways depen-
ding on the type of equipment used:
-valve,
-switch.

30A-6
GENERAL INFORMATION
Brake circuit: Tightening torque
30A
I - FRONT BRAKES
EQ UIPMENT LEVEL SPORT
146250
No. Description Tightening torque (N.m)
(1) Calliper bleed screw10
(2) Guide pin bolts28
(3) Calliper suppor t bolt100
(4) Hub nut280
(5) Brake disc bolt14
-Brake pipe union on the calliper17