RENAULT TWINGO 2009 2.G Chasiss Workshop Manual

37A-2
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
JB1 or JH1 or JH3 or JR5
37A
aRemove the clutch master cylinder supply pipe (3) .
aFit blanking plugs to the brake fluid reservoir and the
clutch master cylinder supply pipe.
aPlace a container under the master cylinder to col-
lect the brake fluid.
aRemove:
-the rigid brake pipe unions (4) on the master cylin-
der,
-the master cylinder nuts (5) on the brake servo,
-the master cylinder (6) and the brake fluid reser-
voir. JH3 or JR5
121343
121347
121346

37A-3
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
JB1 or JH1 or JH3 or JR5
37A
aUsing the workbench, remove:
-the brake fluid reservoir bolt (7) ,
-the brake fluid reservoir.
aFit blanking plugs on the master cylinder.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the master cylinder seals (8) .
aRemove the blanking plugs from the master cylin-
der.
aCarefully pre-fill the master cylinder with the recom-
mended brake fluid (see 30A, General information,
Brake fluid: Specifications, page 30A-18) .II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the brake fluid reservoir,
-the master cylinder making sure that the brake ser-
vo shaft is correctly aligned with the master cylin-
der shaft,
-the rigid brake pipe unions on the master cylinder.
aTighten to torque:
-the brake fluid reservoir bolt (4 Nm),
-the master cylinder nuts on the brake servo (25
Nm),
-the rigid brake pipe unions on the master cylin-
der (15 Nm).
aRemove the blanking plugs from the brake fluid res-
ervoir supply pipe and the clutch master cylinder.
aRefit the clutch master cylinder supply pipe.
aConnect the brake fluid level sensor connector.
III - FINAL OPERATION.
aRefit:
-the injection computer mounting,
-the injection computer (see Petrol injection com-
puter: Removal - Refitting) (17B, Petrol injection).
aFill up the brake fluid reservoir.
aBleed the braking circuit (see 30A, General infor-
mation, Braking circuit: Bleed, page 30A-4) .
aBleed the clutch circuit (see 37A, Mechanical com-
ponent controls, Clutch circuit: Bleed, page 37A-
54) .
aRefit:
-the filler cap of the brake fluid reservoir.
121345
112622
JH3 or JR5
K4M
JH3 or JR5

37A-4
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
JB1 or JH1 or JH3 or JR5
37A
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the battery (see Battery: Removal - Refitting)
(80A, Battery).

37A-5
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
RIGHT-HAND DRIVE
37A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-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).aRemove:
-the fuel vapour recirculation solenoid valve pipes
(1) ,
-the fuel vapour recirculation solenoid valve con-
nector (2) ,
-the fuel vapour recirculation solenoid valve (3) ,
-the fuel vapour recirculation solenoid valve support
nut (4) ,
-the fuel vapour recirculation solenoid valve support
(5) . Tightening torquesm
brake fluid reservoir bolt4 Nm
master cylinder bolts on
the brake servo25 Nm
rigid brake pipe unions
on the master cylinder15 Nm
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
D4F or D7F or K4M
123852

37A-6
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
RIGHT-HAND DRIVE
37A
aRemove:
-the bolts (6) from the bulkhead heat-resistant pro-
tectors,
-the nuts (7) from the bulkhead heat-resistant pro-
tectors,
-the bulkhead heat-resistant protectors (8) .
aRemove:
-the upstream oxygen sensor (see Oxygen sen-
sors: Removal - Refitting) ,
-the bolts (6) from the bulkhead heat-resistant pro-
tector,
-the nuts (7) from the bulkhead heat-resistant pro-
tector, K4M
132436
D4F, and 780
123903
123908

37A-7
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
RIGHT-HAND DRIVE
37A
-the bulkhead heat-resistant protector (8) .
aRemove:
-the timing cover bolt (9) ,
-the timing cover (10) .aUnclip:
-the non-return valve from the support at (11) ,
-the ABS wiring from the support at (12) .
aRemove:
-the nut (13) from the non-return valve and ABS wir-
ing support,
-the non-return valve and ABS wiring support (14) . K4M
131777
123851

37A-8
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
RIGHT-HAND DRIVE
37A
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDrain the secondary brake fluid reservoir (15) with a
syringe.
aPlace a container under the brake master cylinder to
collect the brake fluid from the main reservoir.aRemove the supply pipe (16) from the clutch master
cylinder.
aFit blanking plugs to the brake fluid reservoir and the
clutch master cylinder supply pipe.
123854
JH3 or JR5
123849

37A-9
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
RIGHT-HAND DRIVE
37A
aRemove:
-the clip (17) from the reservoir connecting pipe,
-the reservoir connecting pipe (18) ,
-the rigid brake pipe unions (19) on the master cylin-
der,
-the master cylinder nuts (20) on the brake servo,
-the “master cylinder - reservoir” assembly.
aFit blanking plugs to the master cylinder, the main
brake fluid reservoir supply pipe and the brake fluid
reservoir connecting pipe.
aRemove:
-the bolt (21) from the main brake fluid reservoir,
-the main brake fluid reservoir from the master cylin-
der.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the master cylinder seals (22) .
aRemove the blanking plugs from the master cylin-
der, the main brake fluid reservoir supply pipe and
the brake fluid reservoir connecting pipe.
aCarefully pre-fill the master cylinder with the recom-
mended brake fluid (see 30A, General information,
Brake fluid: Specifications, page 30A-18) .
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the brake fluid reservoir to the master cylinder,
-the "master cylinder - reservoir" assembly, aligning
the brake servo shaft with the master cylinder
shaft,
-the rigid brake pipe unions on the master cylinder.
aTighten to torque:
-the brake fluid reservoir bolt (4 Nm),
-the master cylinder bolts on the brake servo (25
Nm),
-the rigid brake pipe unions on the master cylin-
der (15 Nm).
aRefit:
-the brake fluid reservoir connecting pipe,
-the brake fluid reservoir connecting pipe clip.
123849
112622

37A-10
MECHANICAL COMPONENT CONTROLS
Master cylinder: Removal - Refitting
RIGHT-HAND DRIVE
37A
aRemove the blanking plugs from the brake fluid res-
ervoir and the clutch master cylinder supply pipe.
aRefit the clutch master cylinder supply pipe.
III - FINAL OPERATION.
aRefit:
-the timing cover,
-the bulkhead heat-resistant protectors.
aRefit the bulkhead heat-resistant protector.
aClip onto the support:
-the ABS wiring,
-the non-return valve.
aRefit the support of the non-return valve and the
ABS wiring.
aRefit:
-the fuel vapour recirculation solenoid valve sup-
port,
-the fuel vapour recirculation solenoid valve,
-the petrol vapour recirculation solenoid valve con-
nector,
-the fuel vapour recirculation solenoid valve pipes.
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 secondary brake fluid reservoir.
aBleed the brake circuit (see 30A, General informa-
tion, Braking circuit: Bleed, page 30A-4) . JH3 or JR5
K4M
D4F, and 780
D4F or D7F or K4M

37A-11
MECHANICAL COMPONENT CONTROLS
Brake servo non-return valve: Removal - Refitting
RIGHT-HAND DRIVE
37A
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 front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting, page 35A-1) ,
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-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).
aRemove:
-the bolts (1) from the bulkhead heat-resistant pro-
tector,
-the bulkhead heat-resistant protector (2) .aRemove:
-the upstream oxygen sensor (see Oxygen sen-
sors: Removal - Refitting) (MR 411, 17B, Petrol
injection),
-the bolts (3) from the bulkhead heat-resistant pro-
tectors,
-the nuts (4) from the bulkhead heat-resistant pro-
tectors, D4F or D7F
123866
D4F, and 780
123903
123908