engine RENAULT TWINGO 2009 2.G Panelwork Workshop Manual

TWINGO - Section 4
Contents
Pages
TWINGO - Section 4 ContentsPages
40A GENERAL INFORMATION
Specialised bodywork tools:
Use 40A-1
Vehicle on repair bench:
Description 40A-5
Subframe: Specifications 40A-7
Hollow section inserts: List
and location of components 40A-9
Hollow section inserts:
Precautions for the repair 40A-11
Earths on body: List and
location of components 40A-12
Vehicle structure, front
section: Description 40A-15
Vehicle structure, side
section: Description 40A-17
Vehicle structure, centre
section: Description 40A-19
Vehicle structure, rear
section: Description 40A-21
Vehicle structure, removable
section: Description 40A-23
Structural components to be
positioned on the repair
bench: Description 40A-25
Structural bodywork
documentation: Description 40A-2941A FRONT LOWER STRUCTURE
Front end lower cross
member: General description 41A-1
Front end lower cross
member: Description 41A-2
Radiator mounting cross
member: General description 41A-4
Radiator mounting cross
member: Removal - Refitting 41A-5
Front side member: General
descr iption 41A-6
Front side member, front
section: Description 41A-8
Front side member closure
panel, front section: General
descr iption 41A-11
Front side member closure
panel, front section:
Description 41A-13
Front side member, rear
section: Description 41A-15
Front subframe front
mounting: General
descr iption 41A-17
Front subframe front
mounting: Description 41A-18
Engine stand: General
descr iption 41A-20
Engine stand: Description 41A-21

40A-7
GENERAL INFORMATION
Subframe: Specifications
40A
Description X Dimen-
sion YDimen-
sion ZDiameterAngle (in
degrees)
AFront subframe rear mounting,
without mechanical components205 402.5 71
Front sub-frame rear mounting with
mechanical components205 402.5 38
B1Rear axle assembly front moun-
ting, without mechanical compo-
nents1906 -530 129
Rear axle assembly front moun-
ting, with mechanical components1906 -530 126
BRear axle leader pin without
mechanical components1934 -530 129
CFront left-hand mounting of front
sub-frame without mechanical
components-385 -447 130
Front left-hand mounting of front
sub-frame with mechanical compo-
nents-385 -447 125
Front right-hand mounting of front
sub-frame without mechanical
components-385 465 130
Front right-hand mounting of front
sub-frame with mechanical compo-
nents-385 465 125
ERear shock absorber upper moun-
ting2342 -535 477.5 18.2
FFront shock absorber upper moun-
ting18.5 -545.5 657 48 X: 3.02˚
Y: 1˚
GRear section of front left-hand side
member600 -375 -3.7
GdRear section of front right-hand
side member600 351.6 -5
JRear side member rear leader pin 2858 -481 162.5 10.2
KFront cross member -578.5 277.6 275.7 6
PEngine front mounting -247 483.5 514
QEngine rear mounting -113 483.5 514

40A-16
GENERAL INFORMATION
Vehicle structure, front section: Description
40A
(9) Engine stand (see 41A, Front lower structure, Engine stand: Descrip-
tion, page 41A-21)
(10) Front left-hand wheel arch (see 42A, Front upper structure, Front wheel arch: Des-
cription, page 42A-22)
(11) Front half unit (see 41A, Front lower structure, Front half unit: Des-
cription, page 41A-24)
(12) Front right-hand wheel arch (see 42A, Front upper structure, Front wheel arch: Des-
cription, page 42A-22)
(13) Front wheel arch, front section (see 42A, Front upper structure, Front wheel arch: Des-
cription, page 42A-22) No. Description Classification Type Thickness
(mm)

40A-25
GENERAL INFORMATION
Structural components to be positioned on the repair bench: Description40A
I - PARTS REQUIRING THE USE OF A BODY JIG
BENCH
(1) Front wheel arch
(2) Front half-unit
(3) Engine mounting
(4) Subframe left-hand front mounting
(5) Front side member front section
(6) Rear side member rear section
(7) Rear side member
(8) Rear side member assembly
(9) Rear floor centre cross member
(10) Inner rear wheel archII - FRONT SUBFRAME REAR MOUNTING
121751
121747

40A-27
GENERAL INFORMATION
Structural components to be positioned on the repair bench: Description40A
V - FRONT SHOCK ABSORBER UPPER MOUNTING
The jig supports the underneath of the shock absorber
cup and is centred on the hole (14) of the shock absor-
ber cup.
The jig is used to replace:
-a wheel arch,
-a front half unit.
The jig is also used in straightening.VI - ENGINE MOUNTING
The jig rests on the engine mounting and is centred on
engine mounting securing holes (15) .
The jig is used with the subframe removed for the re-
placement of:
-a front half unit.
-the engine mounting.
VII - FRONT IMPACT CROSS MEMBER MOUNTING
The jig rests vertically against the front end lower cross
member mounting unit, it is centred in the mounting ho-
les (16) .
The jig is used to replace:
-the radiator cross member mounting,
-the front side member completely or partially,.
121753
IMPORTANT
This point contributes to ensuring the front axle
geometry. This point aligns the subframe of the
front axle in relation to the body. This point has a
direct influence on all of the front axle angles.
121753
121754

41A-8
FRONT LOWER STRUCTURE
Front side member, front section: Description
41A
The options for replacing this part are as follows:
-partial replacement,
-complete replacement.
I - COMPOSITION OF THE SPARE PART
Left sideRight-hand side
120643
IMPORTANT
The straightening bench must be used.
120645
No. Description Type Thic-
kness
(mm)
(1) Front side mem-
ber front sectionHLE1.5
(2) Front mounting of
front subframeHLE1.2
(3) Front side mem-
ber inner stiffenerMild
steel1.2
120644
No. Description Type Thic-
kness
(mm)
(4) Engine mounting
reinforcementMild
steel1.5
(5) Engine mounting
stiffener closure
panel componentMild
steel1
(6) Front side mem-
ber front sectionHLE1.5
(7) Front mounting of
front subframeHLE1.2

41A-20
FRONT LOWER STRUCTURE
Engine stand: General description
41A
DESIGN OF THE STRUCTURAL COMPONENT
This is a basic part; it only functions as an engine
mounting.IMPORTANT
Use a repair bench to ensure the positioning of the
points and the geometr y of the axle assemblies.
Note:
The information contained in the following descri-
bes the general repair procedure for all vehicles
having the same design for this part.
Before reading this general information, check that
there are no special notes associated with this vehi-
cle. These special notes will be specified if applica-
ble in other parts of this subsection dealing with the
par t.
Note:
For a detailed description of a particular connec-
tion, see MR 400.
110557

41A-21
FRONT LOWER STRUCTURE
Engine stand: Description
41A
There is only one way of replacing this part:
-complete replacement.
I - COMPOSITION OF THE SPARE PARTII - PART FITTED
120626
IMPORTANT
The straightening bench must be used.
120627
No. Description Type Thic-
kness
(mm)
(1) E ngine support
plateMild
steel2
(2) Engine mounting
height adjusterMild
steel1.8
(3) Engine height
adjuster stiffenerHLE2
120628
WARNING
If the spot welds cannot be made as they were ori-
ginally using an electrical spot welding machine,
they should be replaced with plug welds after holes
have been drilled in the first panel.

41A-22
FRONT LOWER STRUCTURE
Engine stand: Description
41A
III - POSITIONING OF LOCAL ELECTRICAL
EARTHS
121247
121246
IMPORTANT
To avoid damaging the vehicle's electric and elec-
tronic components, the battery and the earths of
any wiring harness near the weld area must be dis-
connected.
The earth of the welding machine must be placed
as close as possible to the weld area.

41A-25
FRONT LOWER STRUCTURE
Front half unit: Description
C44
41A
II - PART IN POSITION
Complete replacementIII - POSITIONING OF THE NEARBY ELECTRICAL
EARTHS
(8) Engine stand HEL/
Mild
steel2
(9) Front cup height
adjusterMild
steel1.3
120629
Note:
For more detailed information on welded connec-
tions with three thicknesses, see MR 400.
IMPORTANT
If the mating faces of the parts to be welded are not
accessible, use EGW plug welds instead of the ori-
ginal resistance welds (see MR 400) No. Description Type Thic-
kness
(mm)
121246
WARNING
To avoid damaging the vehicles electric and electro-
nic components, the earths of any wiring harness
near the weld area must be disconnected.
Position the earth of the welding machine as closely
as possible to the weld area (see MR 400).