RENAULT TWINGO 2009 2.G Chasiss Repair Manual

31A-8
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
EQ UIPMENT LEVEL EA0 or EQUIPMENT LEVEL EA1 or EQUIPMENT LEVEL EA3 or EQUIPMENT LEVEL EA5
or EQUIPMENT LEVEL EAG or EQUIPMENT LEVEL EZ2 or EQUIPMENT LEVEL EZ4
31A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) .
aFit the pedal press to the brake pedal to limit the
outflow of brake fluid.
aUnlock the steering column.
aRemove the front wheel on the side concerned (see
35A, Wheels and tyres, Wheel: Removal - Refit-
ting, page 35A-1) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnlock the brake hose (1) on the brake calliper.
aRemove the brake pads (see 31A, Front axle com-
ponents, Front brake pads: Removal - Refitting,
page 31A-1) . Equipment required
pedal press
Tightening torquesm
guide pin bolts34 N.m
brake hose17 N.m
Note:
The callipers supplied as spare par ts are pre-filled
with br ake fluid.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
119214
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 sur-
rounding components.

31A-9
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
EQ UIPMENT LEVEL EA0 or EQUIPMENT LEVEL EA1 or EQUIPMENT LEVEL EA3 or EQUIPMENT LEVEL EA5
or EQUIPMENT LEVEL EAG or EQUIPMENT LEVEL EZ2 or EQUIPMENT LEVEL EZ4
31A
aRemove:
-the bolts from the guide pins (2) while holding the
nut (3) ,
-the brake calliper from the hose,
-the brake calliper.
REFITTING
I - REFITTING PREPARATION OPERATION
aCheck the condition of the gaiter and calliper piston
(replace defective parts).
aPush the piston back until it is at the end of its bore.
aUsing the cleaning station, clean:
-the calliper mounting,
-the calliper.II - REFITTING OPERATION FOR PART
CONCERNED
aSet the front wheels straight.
aWithout using a tool, screw the calliper to the brake
hose as tightly as possible.
aRefit:
-the brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) ,
-the calliper,
-the new guide pin bolts.
aTorque tighten:
-the guide pin bolts (34 N.m),
-the brake hose (17 N.m).
III - FINAL OPERATION
aRemove the pedal press from the brake pedal.
aBleed the brake circuit (see 30A, General informa-
tion, Braking circuit: Bleed, page 30A-4) .
aRefit the front wheel on the side concerned (see
35A, Wheels and tyres, Wheel: Removal - Refit-
ting, page 35A-1) .
119218
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 sur-
rounding components.
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A-10
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
EQ UIPMENT LEVEL SPORT
31A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the front wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting, page 35A-1) .
aFit a pedal press on the brake pedal to limit the out-
flow of brake fluid.II - REMOVAL OPERATION
aSlightly loosen the brake hose union (1) of the calli-
per.
aRemove:
-the brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) ,
-the brake hose union on the brake calliper.
aFit blanking plugs on the ends of the openings.
aRemove the brake calliper.
REFITTING
I - REFITTING PREPARATION OPERATION
aCheck:
-the condition of the calliper gaiter,
-the condition of the calliper piston; replace it if there
are deep scratches or cracks.
aReplace any faulty parts (see 31A, Front axle com-
ponents, Front brake calliper: Repair, page 31A-
12) .
aClean using a wire brush and BRAKE CLEANER
(see ) (04B, Consumables - Products):
-the calliper mounting,
-the calliper. Special tooling required
Fre. 1190-01Brake calliper piston return
tool.
Equipment required
pedal press
Tightening torquesm
brake hose union13 N.m
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 Front axle components: Precautions for
the repair) ,
- (see Vehicle: Precautions for the repair) (01D,
Mechanical introduction).
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
146248

31A-11
FRONT AXLE COMPONENTS
Front brake calliper: Removal - Refitting
EQ UIPMENT LEVEL SPORT
31A
aPush the piston fully into its housing using the tool
(Fre. 1190-01) part number 77 11 223 715.
II - REFITTING OPERATION
a
aScrew the brake hose union onto the calliper.
aRefit the brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) .
aTorque tighten the brake hose union (13 N.m).
aClean the drips using BRAKE CLEANER (see )
(04B, Consumables - Products).III - FINAL OPERATION
aRemove the pedal press from the brake pedal.
aRefit the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
aBleed the brake circuit (see 30A, General informa-
tion, Braking circuit: Bleed, page 30A-4) .
103115
WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
packaging until they are to be fitted to the vehi-
cle.
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 sur-
rounding components.
IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A-12
FRONT AXLE COMPONENTS
Front brake calliper: Repair
31A
REPAIR
I - REPAIR PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aPosition the pedal press on the brake pedal to limit
the outflow of brake fluid.
aRemove:
-the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
-the front brake calliper (see 31A, Front axle com-
ponents, Front brake calliper: Removal - Refit-
ting, page 31A-8) .II - REPAIR OPERATION FOR PART CONCERNED
aRemove the piston using compressed air, making
sure to insert a wooden block between the calliper
and the piston to avoid damaging it. Any trace of im-
pact on the end panel will render the piston unfit for
use.
aRemove the dust seal.
aRemove the rectangular section seal from the calli-
per groove with a round edged spring blade (feeler
gauge).
aClean the parts using methylated spirit. Special tooling required
Fre. 1190-01Brake calliper piston return
tool.
Equipment required
pedal press
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see Front axle components: Precautions
for the repair) .
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
81546
81545
WARNING
The whole calliper must systematically be
replaced if there are any scratches in the calliper
bore.

31A-13
FRONT AXLE COMPONENTS
Front brake calliper: Repair
31A
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the new rectangular section seal in the calliper
groove,
-the piston (after having smeared it with the grease
supplied in the repair kit) using the (Fre. 1190-01),
-the dust seal.
II - FINAL OPERATION.
aRefit:
-the brake calliper (see 31A, Front axle compo-
nents, Front brake calliper: Removal - Refitting,
page 31A-8) ,
-the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
aRemove the pedal press.
aBleed the brake circuit (see 30A, General informa-
tion, Braking circuit: Bleed, page 30A-4) . IMPORTANT
To avoid any accident, bring the pistons, brake
pads and brake discs into contact by depressing
the brake pad several times.

31A-14
FRONT AXLE COMPONENTS
Front brake calliper mounting: Removal - Refitting
EQ UIPMENT LEVEL EA0 or EQUIPMENT LEVEL EA1 or EQUIPMENT LEVEL EA3 or EQUIPMENT LEVEL EA5
or EQUIPMENT LEVEL EAG or EQUIPMENT LEVEL EZ2 or EQUIPMENT LEVEL EZ4
31A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
-the front brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) .aRemove the guide pin upper bolt (1) while holding
the nut (2) .
aHang the brake calliper on the shock absorber
spring using a safety strap(s). Equipment required
safety strap(s)
Tightening torquesm
brake calliper mounting
bolts100 N.m
guide pin upper bolt29 N.m
119218
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 sur-
rounding components.

31A-15
FRONT AXLE COMPONENTS
Front brake calliper mounting: Removal - Refitting
EQ UIPMENT LEVEL EA0 or EQUIPMENT LEVEL EA1 or EQUIPMENT LEVEL EA3 or EQUIPMENT LEVEL EA5
or EQUIPMENT LEVEL EAG or EQUIPMENT LEVEL EZ2 or EQUIPMENT LEVEL EZ4
31A
II - REMOVAL OPERATION
aRemove:
-the brake calliper mounting bolts (3) ,
-the brake calliper mounting.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace the guide pin upper bolt.
aUsing the cleaning station, clean:
-the brake calliper mounting,
-the brake calliper.
aCoat the brake calliper mounting bolts with HIGH
STRENGTH THREAD LOCK (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) before refitting them.
II - REFITTING OPERATION
aRefit:
-the brake calliper mounting,
-the brake calliper mounting bolts.
aTorque tighten the brake calliper mounting bolts
(100 N.m).
III - FINAL OPERATION
aFit the front brake calliper.aRefit the upper bolt on the guide pin while holding
the nut.
aTorque tighten the guide pin upper bolt (29 N.m)
while holding the nut.
aRefit:
-the front brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) ,
-the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .
119219

31A-16
FRONT AXLE COMPONENTS
Front brake calliper mounting: Removal - Refitting
EQ UIPMENT LEVEL SPORT
31A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) ,
-the front brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) .II - REMOVAL OPERATION
aRemove:
-the calliper mounting bolts (1) ,
-the calliper mounting.
REFITTING
I - REFITTING PREPARATION OPERATION
aClean using a wire brush and BRAKE CLEANER
(see Vehicle: Parts and consumables for the re-
pair) (04B, Consumables - Products):
-the calliper mounting,
-the calliper,
-the hub carrier.
aparts always to be replaced: Front brake calliper
mounting bolt.
II - REFITTING OPERATION
aRefit the calliper mounting.
aTorque tighten the calliper mounting bolts (100
N.m).
III - FINAL OPERATION
aRefit:
-the front brake pads (see 31A, Front axle compo-
nents, Front brake pads: Removal - Refitting,
page 31A-1) , Tightening torquesm
calliper mounting bolts100 N.m
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 Front axle components: Precautions for
the repair) ,
- (see Vehicle: Precautions for the repair) (01D,
Mechanical introduction).
145125

31A-17
FRONT AXLE COMPONENTS
Front brake calliper mounting: Removal - Refitting
EQ UIPMENT LEVEL SPORT
31A
-the front wheel (see 35A, Wheels and tyres,
Wheel: Removal - Refitting, page 35A-1) .