lock RENAULT TWINGO 2009 2.G Panelwork Workshop Manual

40A-11
GENERAL INFORMATION
Hollow section inserts: Precautions for the repair
40A
The expanding inserts ensure that the vehicle cavities
are sealed and soundproofed. They react to the tempe-
rature when the bodywork is immersed in the catapho-
retic bath at the factory. These conditions cannot be
reproduced on the bodywork.
As inserts are not recoverable, always replace expan-
ding inserts.
The inserts supplied by the Parts Department are
identical to the original parts.
To obtain the same sealing and soundproofing proper-
ties, carry out the following operations:
-clean the bonding surfaces with heptane,
-if necessary, block the holes in the insert using pieces
cut from a soundproofing pad.
-apply a bead of preformed trim sealing mastic around
and inside the insert holes,
-fit the insert by compressing the mastic.
In some cases, it is possible to replace the accessible
part of the insert only, which must be cut out of the re-
placement part.WARNING
Do not refit the part after compressing the bead.
When EGW welding, protect the inserts from spat-
ter and heat dispersion.
For example, use a heat shield.

42A-9
FRONT UPPER STRUCTURE
Front end panel: Removal - Refitting
42A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the front bumper ( (see Front bumper: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip the wiring harness.
aRemove the bonnet opening cable.
aRemove the bolt (1) from the coolant bottle.
aUnclip the coolant bottle.
aRemove:
-the bolt (2) from the cooling radiator deflector,
-the bolts (3) from the cooling radiator support,
-the bolts (4) .
aUndo:
-the nut (5) ,
-the bolts (6) .
aRemove the front end panel.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the front end panel,
121037
Note:
The bolts (4) and (6) can be accessed between
the front end lower cross member and the coo-
ling radiator.
Note:
The front end panel is made up of the front upper
cross member and the headlight carrier panels.

42A-10
FRONT UPPER STRUCTURE
Front end panel: Removal - Refitting
42A
-the bolts (4) ,
-the bolts (3) on the cooling radiator support,
-the bolt (2) on the cooling radiator deflector.
aTighten:
-The bolts (6) ,
-the nut (5) .
aClip on the coolant bottle.
aRefit the bolt (1) on the coolant bottle.
aPosition the bonnet opening release cable.
aClip on the wiring harness.
II - FINAL OPERATION.
aRefit:
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the front bumper ( (see Front bumper: Removal -
Refitting) ).

42A-11
FRONT UPPER STRUCTURE
Headlight carrier panel: Removal - Refitting
42A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection),
-the halogen headlight (see Halogen headlight:
Removal - Refitting) (MR 411, 80B, Headlights),
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (MR 412, 52A, Non-side opening ele-
ment mechanisms),
-the front upper cross member (see 42A, Front up-
per structure, Front upper cross member: Re-
moval - Refitting, page 42A-13) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aLoosen nut (2) .
aRemove:
-the bolts (1) ,
-the headlight carrier panel.
REFITTING
I - REFITTING PREPARATIONS OPERATION
a
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the headlight carrier panel,
-the bolts (1) .
aTighten the nut (2) .
III - FINAL OPERATION.
aRefit:
-the front upper cross member (see 42A, Front up-
per structure, Front upper cross member: Re-
moval - Refitting, page 42A-13) ,
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (MR 412, 52A, Non-side opening ele-
ment mechanisms),
-the halogen headlight (see Halogen headlight:
Removal - Refitting) (MR 411, 80B, Headlights),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection).
121251
WARNING
For any adjustment or removal - refitting proce-
dure where it is necessar y to separate a bolted
connection, reapply the mating and sealing anti-
corrosion protection to the bolts using filler mas-
tic in a pre-formed bead.

42A-13
FRONT UPPER STRUCTURE
Front upper cross member: Removal - Refitting
42A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove:
-the front bumper ( (see Front bumper: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip the wiring harness.
aRemove the bonnet opening cable.
aRemove the bolt (1) from the coolant bottle.
aUnclip the coolant bottle.
aRemove:
-the bolt (2) from the cooling radiator deflector,
-the front upper cross member bolts (3) .
aUndo the bolts (4) .
aRemove the front upper cross member.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the front upper cross member,
-the bolts (3) ,
-the bolt (2) on the cooling radiator deflector.
aTighten the bolts (4) .
aClip on the coolant bottle.
aRefit the bolt (1) on the coolant bottle.
aPosition the bonnet opening release cable.
aClip on the wiring harness.
II - FINAL OPERATION.
aRefit:
-the bonnet catch ( (see Bonnet lock: Removal -
Refitting) ),
-the headlights ( (see Halogen headlight: Remo-
val - Refitting) ),
-the front bumper ( (see Front bumper: Removal -
Refitting) ).
121036
Note:
The bolts (4) can be accessed between the front
end lower cross member and the cooling radia-
tor.

42A-26
FRONT UPPER STRUCTURE
Dashboard cross member: Removal - Refitting
42A
REMOVAL
a
I - REMOVAL PREPARATION OPERATION
aLock the airbag computer using the Diagnostic tool
(see Fault finding - Replacement of components)
(MR 413, 88C, Airbags and pretensioners).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).
aRemove:
-the dashboard (see Dashboard: Removal - Refit-
ting) (MR 412, 57A, Interior equipment),
-the steering column (see Steering column: Re-
moval - Refitting) (MR 411, 36A, Steering assem-
bly).II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the dashboard cross member wiring harnesses,
-the flange bolts (1) ,
-the flange.
aRemove the bulkhead tie-rod bolt (2) . Equipment required
Diagnostic tool
Tightening torquesm
the dashboard cross
member bolts21 Nm
windscreen aperture
lower cross member tie-
rod bolt21 Nm
the bulkhead tie-rod bolt8 Nm
the flange bolts21 Nm
IMPORTANT
To avoid any risk of triggering when working on
or near a pyrotechnic component (airbags or pre-
tensioners), lock the airbag computer using the
diagnostic tool.
When this function is activated, all the trigger
lines are inhibited and the airbag warning light on
the instrument panel lights up continuously (igni-
tion on).
IMPORTANT
Never handle the pyrotechnic systems (preten-
sioners or airbags) near to a source of heat or
naked flame - they may be triggered.
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121240

42A-27
FRONT UPPER STRUCTURE
Dashboard cross member: Removal - Refitting
42A
aRemove:
-the bolts (3) ,
-the windscreen aperture lower cross member tie-
rod bolt (4) ,
-the dashboard cross member bolts (5) ,
-the dashboard cross member.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the dashboard cross member,
-the dashboard cross member bolts (5) .
-the windscreen aperture lower cross member tie-
rod bolt (4) ,
-the bolt (3)
-the bulkhead tie-rod bolts (2) ,
-the flange,
-the flange bolts (1) ,
-the dashboard cross member wiring harnesses,
aTorque tighten:
-the dashboard cross member bolts (21 Nm),
-windscreen aperture lower cross member tie-
rod bolt (21 Nm),
-the bulkhead tie-rod bolt (8 Nm),
-the flange bolts (21 Nm).II - FINAL OPERATION.
aRefit:
-the steering column (see Steering column: Re-
moval - Refitting) (MR 411, 36A, Steering assem-
bly),
-the dashboard (see Dashboard: Removal - Refit-
ting) (MR 412, 57A, Interior equipment).
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).
aUnlock the airbag computer using the Diagnostic
tool (see Fault finding - Replacement of compo-
nents) (MR 413, 88C, Airbags and pretensioners).
121239

45A-3
TOP OF BODY
Roof: Description
45A
Level off the weld residue (see MR 400, Basic instruc-
tions for structural bodywork repair, 40A, General
information, Tool for levelling off weld residue:
Use).
2 - Preparation before assembly
a - Positioning and adjustment
Position the spare part, adjust it and fit it using locking
pliers (see MR 400, Basic instructions for structural
bodywork repair, 40A, General information, Tool
for adjusting and supporting a structural compo-
nent: Use).
If necessary, reassemble the adjacent components
and check the panel gaps.
b - Marking and identifying the joints
Mark the optimum position of the roof with masking
tape between the spare part and the body side (2) .
Remove the replacement part.
c - Preparing the mating faces on the spare part
Gently sand the internal mating faces on the bonding
zones of the spare part with P320 dry sand paper or a
red abrasive pad, without removing the protection.
Prepare the rest of the replacement part according to
the joint type.
d - Preparing the mating faces on the vehicle
Gently sand the internal mating face bonding zones on
the vehicle with P320 dry sand paper or a red abrasive
pad, without removing the protection.
Prepare the rest of the vehicle according to the joint ty-
pe.e - Apply the protection before assembly
Apply the spare part and vehicle protection before as-
sembly (see MR 400, Basic instructions for structu-
ral bodywork repair, 40A, General information, Pre-
assembly anticorrosion protection product: Use).
3 - Assembly
a - Application of the bonding products
Degrease the bonding zones on the replacement part
and the vehicle using heptane.
Apply a cement bead of M.J. Pro to the roof cross
members (3) .
Apply a bead of HIGH PERFORMANCE STRUCTU-
RAL ADHESIVE to the entire internal mating face on
the body side (see MR 400, Basic instructions for
structural bodywork repair, 40A, General informa-
tion, Connection by rigid bonding: Description).
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121626
120077

45A-5
TOP OF BODY
Roof: Description
45A
Hold the spare part with locking pliers (at the front and
rear cross members) and the safety strap(s) to posi-
tion it securely according to the markings made earlier
(5) (see MR 400, Basic instructions for structural
bodywork repair, 40A, General information, Tools
for adjusting and supporting a structural compo-
nent: Use).
Let the adhesive dry for 10 hours at an ambient tem-
perature or for 2 hours at 60˚C.
c - Making the other joints
Make the rest of the replacement part joints.
4 - Finishing after assembly
Applying finishing product
Prime the side bonding areas.Apply a finishing seal, type M. J. Pro to the side bon-
ding areas.
Scrape off the surplus of bonding before it dries using
the (Car. 1786).
121630
Note:
To fit the safety straps without removing the quarter
panel windows, use 3 safety straps.
121631

47A-3
SIDE OPENING ELEMENTS
Front side door: Stripping - rebuilding
47A
STRIPPING
aThe order of the operations described below applies
specifically to replacing the door.
STRIPPING OPERATION FOR PART CONCERNED
aRemove:
-the door mirror (see Door mirror: Removal - Re-
fitting) (MR 412, 56A, Exterior equipment),
-the front side door trim (see Front side door trim:
Removal - Refitting) (MR 412, 72A, Side opening
element trim),
-the front side door exterior weatherstrip (see Front
side door exterior weatherstrip: Removal - Re-
fitting) (MR 412, 66A, Window sealing),
-the front side door interior weatherstrip.
-the front side door glass run channel (see Front
side door window run channel: Removal - Refit-
ting) (MR 412, 66A, Window sealing),
-the door sealing film (see Door sealing film: Re-
moval - Refitting) (MR 412, 65A, Opening ele-
ment sealing),
-the front side sliding door window (see Front side
door sliding window: Removal - Refitting) (MR
412, 54A, Windows),
-the front side door electric window winder mecha-
nism (see Front side door electric window me-
chanism: Removal - Refitting) (MR 412, 51A,
Side opening element mechanisms) or the front
side door manual window winder mechanism (see
Front side door manual window winder mecha-
nism: Removal - Refitting) (MR 412, 51A, Side
opening element mechanisms),
-the exterior door handle (see Exterior door han-
dle: Removal - Refitting) (MR 412, 51A, Side ope-
ning element mechanisms),
-the front side door lock barrel (see Front side door
lock barrel: Removal - Refitting) (MR 412, 51A,
Side opening element mechanisms),
-the front side door lock (see Front side door lock:
Removal - Refitting) (MR 412, 51A, Side opening
element mechanisms),
-the front side door check strap (see Front side
door check strap: Removal - Refitting) (MR 412,
51A, Side opening element mechanisms).aRemove:
-the rivet (1) ,
-the front side door trim mounting bracket (1) ,
-the front door rubbing strip (see Front side door
protective strip: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the wiring harness.
REBUILDING
REBUILDING OPERATION FOR PART
CONCERNED
aRefit:
-the wiring harness,
-the front door rubbing strip (see Front side door
protective strip: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the front side door trim mounting bracket (1) ,
-the rivet (1) ,
-the front side door check strap (see Front side
door check strap: Removal - Refitting) (MR 412,
51A, Side opening element mechanisms),
-the front side door lock (see Front side door lock:
Removal - Refitting) (MR 412, 51A, Side opening
element mechanisms),
-the front side door lock barrel (see Front side door
lock barrel: Removal - Refitting) (MR 412, 51A,
Side opening element mechanisms), Note:
It is possible to carry out the str ipping operations
on the vehicle before removing the door.
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