air RENAULT TWINGO 2009 2.G Chasiss Repair Manual

37A-53
MECHANICAL COMPONENT CONTROLS
Clutch pedal switch: Removal - Refitting
CRUISE CONTROL, and 5-SPEED MANUAL GEARBOX
37A
REFITTING
I - REFITTING PREPARATIONS OPERATION
a
aMeasure dimension of the piston (4) . If the dimen-
sion (x) is less than 15 mm, carefully pull the end of
the piston (4) to adjust the dimension to between 15
mm minimum and 17 mm maximum.
II - REFITTING OPERATION FOR PART
CONCERNED
aDepress the clutch pedal by hand.
aFit the clutch pedal switch to the pedal.
aLock the clutch pedal switch by turning it a quarter of
a turn clockwise.
aAt the same time, carefully return the clutch pedal.
III - FINAL OPERATION.
aConnect the clutch pedal switch connector.aBe sure to carry out a repair check using Diagnostic
tool.
aRefit the dashboard glovebox.
108436
WARNING
Whenever the clutch pedal switch piston is com-
pletely removed, the switch must be replaced.
WARNING
The switch must be replaced if handling of the
piston results in three adjustments being made.
Note:
The clutch pedal switch has an automatic adjust-
ment feature, adapting to the pedal position.
The automatic adjustment makes a clicking noise
when in operation.

37A-54
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleed
JH3 or JR5
37A
Bleed in the event of:
-dead travel,
-pedal at mid-travel,
-pedal to the floor,
-poor gear changing.
I - PRECAUTIONS DURING REPAIR
Risks relating to contamination.
aThe hydraulic clutch system is very sensitive to con-
tamination. The risks caused by contamination are:
-impossible to change gears,
-damage to or destruction of the clutch system,
-leaks on the hydraulic circuit.
All the operations on the hydraulic clutch circuit sys-
tem must be carried out under excellent cleanliness
conditions. This ensures that no impurities enter the
hydraulic circuit during the operation.
The cleanliness principles apply to all components
of the hydraulic clutch circuit.
Items causing contamination are:
-metal or plastic swarf,
-fibres:
•cardboard,
•brushes,
•paper,
•clothing,
•cloth,
•dust and particles in the air,
•etc.
Cleaning cloths.
aUse lint-free cleaning cloths (see Products recom-
mended for the repair) (04B, Consumables - Prod-
ucts).
Each cloth must only be used once.There are two types of equipment used to bleed the
clutch circuit:
aARC50 via the brake fluid reservoir.
aSyringe via the bleed hole located on the clutch
slave cylinder.
There are two procedures used to bleed the clutch
circuit:
aIf no parts of the hydraulic clutch circuit are remo-
ved:
-Carry out the bleed operation using the ARC50 via
the brake fluid reservoir or using a new syringe via
the bleed hole located on the clutch slave cylinder.
aIf no parts of the hydraulic clutch circuit are remo-
ved:
-Only carry out the bleed operation using a new sy-
ringe by injecting the brake fluid via the bleed hole
on the clutch slave cylinder.
Consumables required for the repair:
aBleed the clutch circuit using approved (see Vehi-
cle: Parts and consumables for the repair) brake
fluid (04B, consumables - products).
II - PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the engine undertray. Equipment required
brake circuit bleeding device
hydraulic circuit bleed syringe
Note:
-Even the tiniest air bubble in the circuit can
cause faulty operation (pedal failing to return
properly, crunching sound when changing gear,
etc.).
-Incorrect bleeding can lead to incorrect detec-
tion of faults and unnecessary part replace-
ments.

37A-56
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleed
JH3 or JR5
37A
Bleed screw with two clips.
aTo open the bleed screw, lower the clip (6) and lift
the clip (7) while pulling by one notch.
III - BLEED PROCEDURE IF NO PARTS OF THE
HYDRAULIC CIRCUIT ARE REMOVED
1 - Bleed using the ARC50.
aKeep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure conti-
nuity of the hydraulic circuit during the bleed opera-
tion.aConnect the brake circuit bleeding device (after
having received Renault approval) to the master cyl-
inder reservoir (see the instructions for the equip-
ment).
aRemove the bleed plug from the clutch slave cylin-
der.
aConnect a transparent pipe to the bleed hole running
to an empty container placed under the bleed hole.
aOpen the bleed screw.
aOpen the circuit between the bleeding device and
the brake fluid reservoir.
aLet the brake fluid run until all air bubbles have been
released.
aStop the bleeding device to dump the pressure in the
clutch circuit.
aClose the bleed screw.
aRemove the transparent pipe from the bleed hole.
aRefit the bleed plug.
aTop up the brake fluid level in the master cylinder
reservoir after disconnecting the bleed device.
aDisengage and engage the clutch quickly around
twenty times.
aCheck that the clutch system is operating correctly.
aRepeat the bleed operation if necessary.
aCheck the adjustment of the switch. (see 37A, Me-
chanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-52) (37A,
mechanical control elements).
113732
Note:
Ta k e c are not to disrupt the adjustment of the
clutch start of travel switch.

37A-57
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleed
JH3 or JR5
37A
2 - Bleed using a new syringe.
aKeep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure conti-
nuity of the hydraulic circuit during the bleed opera-
tion.
aRemove the bleed plug from the clutch slave cylin-
der.
aConnect a transparent pipe of sufficient length to the
bleed hole (at least thirty centimetres) in order to
place it at the same height as the reservoir.
aOpen the bleed screw.
aFill the brake fluid master cylinder reservoir until
brake fluid flows out of the bleed screw.
aConnect a new hydraulic circuit bleed syringe
filled with a useful volume of 60 ml of approved
brake fluid to the end of the transparent pipe.
aSlowly inject the entire contents of the syringe into
the hydraulic clutch circuit without injecting any of
the air from the top section of the syringe.
aClose the bleed screw.
aRemove the transparent pipe from the bleed hole.
aRefit the bleed plug.
aTop up the brake fluid level in the master cylinder
reservoir.
aDisengage and engage the clutch quickly around
twenty times.
aCheck that the clutch system is operating correctly.
aRepeat the bleed operation if necessary.
aCheck the adjustment of the switch. (see 37A, Me-
chanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-52) (37A,
mechanical control elements).IV - BLEED PROCEDURE IF PARTS OF THE
HYDRAULIC CIRCUIT ARE REMOVED.
a
Note:
Take care not to disrupt the adjustment of the
clutch start of travel switch.
Note:
The transparent pipe must remain at the same
height as the master cylinder reservoir to prevent
air from entering inside the clutch circuit.
WARNING
The master cylinder pipe must be disconnected
from its take-off point on the br ake fluid reservoir,
to avoid any foreign matter penetrating inside the
hydraulic brake circuit.
WARNING
Prepare for the fl ow of fluid and protect the sur-
rounding components.
Note:
Prefill the hydraulic circuit pipe equipped with a
filter.
Position the filter head facing downwards to
ensure that it fills.

37A-59
MECHANICAL COMPONENT CONTROLS
Clutch circuit: Bleed
JH3 or JR5
37A
aPrefill the hydraulic tappet using the new syringe (by
gravity).
aRefit the part(s) concerned.V - BLEED PROCEDURE AFTER A REMOVING A
COMPONENT OF THE HYDRAULIC CIRCUIT.
aKeep the clutch pedal in the upper position using a
strap attached to the steering wheel to ensure conti-
nuity of the hydraulic circuit during the bleed opera-
tion.
aRemove the bleed plug from the clutch slave cylin-
der.
aConnect a transparent pipe of sufficient length to the
bleed hole (at least thirty centimetres) in order to
place it at the same height as the reservoir.
aOpen the bleed screw.
aFill the brake fluid master cylinder reservoir until
brake fluid flows out of the bleed screw.
aConnect a new syringe containing 60 ml of ap-
proved brake fluid to the end of the transparent pipe.
aSlowly inject the entire contents of the syringe into
the hydraulic clutch circuit without injecting any of
the air from the top section of the syringe.
aClose the bleed screw.
aRemove the transparent pipe from the bleed hole.
aRefit the bleed plug.
aTop up the brake fluid level in the master cylinder
reservoir.
aDisengage and engage the clutch quickly around
twenty times.
aCheck that the clutch system is operating correctly.
aRepeat the bleed operation if necessary.
aCheck the adjustment of the switch. (see 37A, Me-
chanical component controls, Clutch pedal
switch: Removal - Refitting, page 37A-52) (37A,
mechanical control elements).
141809
Note:
Take care not to disrupt the adjustment of the
clutch start of travel switch.
Note:
The transparent pipe must remain at the same
height as the master cylinder reser voir to prevent
air from enter ing inside the clutch circuit.

38C-2
ANTI-LOCK BRAKING SYSTEM
Hydraulic brake unit: Removal - Refitting
K9K, and LEFT-HAND DRIVE
38C
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).
aPosition the pedal press on the brake pedal to limit
the outflow of brake fluid.
aRemove:
-the front wheel on the passenger side (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1) ,
-the front wheel arch liner, on the passenger side
(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),
-the air filter box (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture).aRemove:
-the bolts (1) from the lifting eye on the right-hand
side,
-the lifting eye on the right-hand side (2) ,
-the rigid pipe (3) from the EGR circuit.
aRemove the clip (4) from the soundproofing.
aMove the soundproofing aside (5) to access the hy-
draulic unit. Equipment required
pedal press
Tightening torquesm
hydraulic unit bolts on
its inter mediate bracket8 Nm
hydraulic unit inter medi-
ate bracket bolts on the
main hydraulic unit
mounting6.5 Nm
hydraulic unit main
mounting bolts on the
body8 Nm
rigid brake pipe unions
on the hydraulic unit13 Nm
112329
121358

38C-4
ANTI-LOCK BRAKING SYSTEM
Hydraulic brake unit: Removal - Refitting
K9K, and LEFT-HAND DRIVE
38C
aRemove:
-the hydraulic assembly intermediate bracket bolts
(10) ,
-the « hydraulic unit intermediate bracket - hydraulic
unit » assembly (11) from the main mounting,
-the hydraulic unit bolts (12) from its intermediate
bracket,
-the hydraulic unit from its intermediate bracket.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the hydraulic unit onto its intermediate bracket,
-the hydraulic unit bolts onto its intermediate brack-
et.
aTorque tighten the hydraulic unit bolts on its inter-
mediate bracket (8 Nm).
aRefit:
-the « hydraulic unit intermediate bracket - hydraulic
unit » assembly onto the main mounting,
-the hydraulic unit intermediate bracket bolts onto
the main hydraulic unit mounting.
aTorque tighten the hydraulic unit intermediate
bracket bolts on the main hydraulic unit mount-
ing (6.5 Nm).aRefit:
-the « hydraulic unit mounting - hydraulic unit » as-
sembly on the body,
-the hydraulic unit main mounting bolts on the body.
aTorque tighten the hydraulic unit main mounting
bolts on the body (8 Nm).
II - FINAL OPERATION.
aRemove the blanking plugs.
aFit and tighten the rigid brake pipe unions on the hy-
draulic unit.
aTorque tighten the rigid brake pipe unions on the
hydraulic unit (13 Nm).
aConnect the computer connector on the hydraulic
unit.
aFit the bulkhead soundproofing.
aRefit:
-the soundproofing clip,
-the rigid exhaust gas recirculation circuit pipe,
-the lifting eye on the right-hand side,
-the air filter box (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (MR 412, 56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 412, 56A, Exterior
equipment),
-the front wheel arch liner, on the passenger side
(see Front wheel arch liner: Removal - Refitting)
(MR 412, 55A, Exterior protection),
-the front wheel on the passenger side (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1) .
aRemove the pedal press from the brake pedal.
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).
aBleed the braking circuit (see 30A, General infor-
mation, Braking circuit: Bleed, page 30A-4) .
121456

38C-5
ANTI-LOCK BRAKING SYSTEM
Hydraulic brake unit: Removal - Refitting
D4F or D7F, and LEFT-HAND DRIVE
38C
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).
aPosition the pedal press on the brake pedal to limit
the outflow of brake fluid.
aRemove:
-the front wheel on the passenger side (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1) ,
-the front wheel arch liner, on the passenger side
(see Front wheel arch liner: Removal - Refitting)
(MR 412, 55A, Exterior protection),
-the ignition coil (see Coils: Removal - Refitting)
(MR 411, 17A, Ignition),
-the fuel vapour recirculation circuit solenoid valve
(see Fuel vapour absorber: Removal - Refitting)
(MR 411, 14A, Emission control),
-the air filter box (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture).aDisconnect the hydraulic unit computer connector
(1) .
aUndo the rigid brake pipe unions (2) on the hydraulic
unit.
aInsert the blanking plugs. Equipment required
pedal press
Tightening torquesm
hydraulic unit bolts on
its inter mediate bracket8 Nm
hydraulic unit inter medi-
ate bracket bolts on the
main hydraulic unit
mounting6.5 Nm
hydraulic unit main
mounting bolts on the
body8 Nm
rigid brake pipe unions
on the hydraulic unit13 Nm
121359
121360
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.

38C-7
ANTI-LOCK BRAKING SYSTEM
Hydraulic brake unit: Removal - Refitting
D4F or D7F, and LEFT-HAND DRIVE
38C
-the hydraulic unit main mounting bolts on the body.
aTorque tighten the hydraulic unit main mounting
bolts on the body (8 Nm).
II - FINAL OPERATION.
aRemove the blanking plugs.
aFit and tighten the rigid brake pipe unions on the hy-
draulic unit.
aTorque tighten the rigid brake pipe unions on the
hydraulic unit (13 Nm).
aConnect the computer connector on the hydraulic
unit.
aRefit:
-the air filter box (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the fuel vapour recirculation circuit solenoid valve
(see Fuel vapour absorber: Removal - Refitting)
(MR 411, 14A, Emission control),
-the ignition coil (see Coils: Removal - Refitting)
(MR 411, 17A, Ignition),
-the front wheel arch liner, on the passenger side
(see Front wheel arch liner: Removal - Refitting)
(MR 412, 55A, Exterior protection),
-the front wheel on the passenger side (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1) .
aRemove the pedal press from the brake pedal.
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).
aBleed the braking circuit (see 30A, General infor-
mation, Braking circuit: Bleed, page 30A-4) .

38C-8
ANTI-LOCK BRAKING SYSTEM
Hydraulic brake unit: Removal - Refitting
D4F, and 780, and LEFT-HAND DRIVE – K4M, and LEFT-HAND DRIVE
38C
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
aPosition the pedal press on the brake pedal to limit
the outflow of brake fluid.
aRemove:
-the passenger side front wheel (see 35A, Wheels
and tyres, Wheel: Removal - Refitting, page
35A-1) ,
-the front wheel arch liner (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion).
aRemove the air filter housing (see Air filter unit: Re-
moval - Refitting) (12A, Fuel mixture).aDisconnect the fuel vapour rebreathing solenoid
valve union (1) .
aRemove the fuel vapour rebreathing solenoid valve
(2) .
aRemove the bolts (3) from the bulkhead heat shield.
aMove the bulkhead heat shield (4) to one side. Equipment required
pedal press
refrigerant charging station
Tightening torquesm
hydraulic unit bolts on
its inter mediate bracket8 Nm
intermediate bracket
bolts on the hydraulic
unit main bracket8 N.m
hydraulic unit main
mounting bolts on the
body8 Nm
rigid brake pipe unions
on the hydraulic unit13 Nm
D4F, and 780
109625
122384