roof RENAULT TWINGO RS 2009 2.G Panelwork Workshop Manual

Contents
Rear end panel: General
descr iption 44A-24
Rear end panel: Description 44A-25
45A TOP OF BODY
Roof: General description 45A-1
Roof: Description 45A-2
Roof front section:
Description 45A-6
Roof rear section:
Description 45A-7
Roof front cross member:
General description 45A-8
Roof centre cross member:
General description 45A-9
Roof rear cross member:
General description 45A-10
47A SIDE OPENING ELEMENTS
Front side door: Removal -
Refitting 47A-1
Front side door: Stripping -
rebuilding 47A-3
Front side door: Adjustment 47A-5
Fuel filler flap co ver:
Removal - Refitting 47A-8
48A NON-SIDE OPENING ELEMENTS
Bonnet: Removal - Refitting 48A-1
Bonnet: Stripping -
Rebuilding 48A-3
Bonnet: Adjustment 48A-4
Tailgate: Removal - Refitting 48A-6 44A REAR UPPER STRUCTURETailgate: Stripping -
Rebuilding 48A-8
Tailgate: Adjustment 48A-10 48A NON-SIDE OPENING ELEMENTS

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.

40A-17
GENERAL INFORMATION
Vehicle structure, side section: Description
40A
SIDE STRUCTURE
120919
No. Description Classification Type Thickness
(mm)
(1) Roof drip moulding lining (see MR 400)HLE1.3
(2) Normal roof front cross member (see 45A, Top of body, Roof
front cross member: General
description, page 45A-8) Mild
steel1
(3) Roof rear cross member (see 45A, Top of body, Roof
rear cross member: General
description, page 45A-10) HLE1.2
(4) Sill pane stiffener (see 41C, Side lower structure, Sill panel stiffener: Des-
cription, page 41C-15)
(5) Sill panel reinforcement (see 41C, Side lower structure, Sill panel reinforce-
ment: Description, page 41C-13)
(6) A-pillar reinforcement (see 43A, Side upper structure, A-pillar reinforcement:
Description, page 43A-6)
(7) Sill panel closure panel (see 41C, Side lower structure, Sill panel closure panel:
Description, page 41C-10)

40A-18
GENERAL INFORMATION
Vehicle structure, side section: Description
40A
(8) B-pillar reinforcement (see 43A, Side upper structure, B-pillar reinforcement:
Description, page 43A-10)
(9) Windscreen pillar lining (see Windscreen pillar lining: Description)
(10) A-pillar (see 43A, Side upper structure, A-pillar: Description,
page 43A-2)
(11) Roof centre cross member (see Roof centre cross member: Description)
(12) Front section of roof (see 45A, To p of body, Roof front section: Description,
page 45A-6)
(13) Sill panel (see 41C, Side lower structure, Sill panel: Description,
page 41C-5)
(14) Roof (see 45A, Top of body, Roof: Description, page 45A-2)
(15) Upper body (see 43A, Side upper structure, Upper body: Descrip-
tion, page 43A-17)
(16) Rear section of roof (see 45A, Top of body, Roof rear section: Description,
page 45A-7) No. Description Classification Type Thickness
(mm)

43A-17
SIDE UPPER STRUCTURE
Upper body: Description
43A
To replace this part, also order the A-pillar insert (A) .
There is only one way of replacing this part:
-complete replacement.
I - COMPOSITION OF THE SPARE PARTII - PART IN POSITION
Complete replacement
Section B
125414
121004
No. Description Type Thic-
kness
(mm)
(1) Body side Mild
steel0.75
(2) Roof bar moun-
ting reinforce-
mentMild
steel1.5
121001
121002

44A-2
REAR UPPER STRUCTURE
Rear wing panel: Description
C44
44A
the options for replacing this part are as follows:
-partial replacement,
-complete replacement.
I - COMPOSITION OF THE SPARE PARTII - PART IN POSITION
1 - Partial replacement
125413
121006
No. Description Type Thickness
(1) Body side Mild
steel0.75
(2) Roof bar moun-
ting reinforce-
mentMild
steel1.5
121008

44A-17
REAR UPPER STRUCTURE
Quarter panel lining: Description
44A
To replace this part, order the roof drip moulding lining
insert (A) .
There is only one way of replacing this part:
-complete replacement.I - COMPOSITION OF THE SPARE PART
125416
EQUIPMENT LEVEL EA0 or EQUIPMENT LEVEL
EA1 or EQUIPMENT LEVEL EA3 or EQUIPMENT
LEVEL EA5 or EQUIPMENT LEVEL EAG or EQUI-
PMENT LEVEL EZ2 or EQUIPMENT LEVEL EZ4
121913

45A-1
TOP OF BODY
Roof: General description
45A
DESIGN OF THE STRUCTURAL COMPONENT
This is a basic part; its only function is that of a roof.
The special feature of the roof is that it is laser welded
to the body sides.
For vehicles fitted with a sunroof, the roof only has a
front section and a rear section.
If there are other issues regarding access to mating fa-
ces, the various replacement options are described in
the basic instructions for structural bodywork repair
(see MR 400). 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 the following general information,
make sure that there are no special notes associa-
ted with the vehicle. These special notes are speci-
fied if necessary in other par ts of the sub-section
dealing with the component.
Note:
For a detailed description of a particular connec-
tion, see MR 400.
121044

45A-2
TOP OF BODY
Roof: Description
45A
There is only one way of replacing this part:
-complete replacement.
I - COMPOSITION OF THE SPARE PARTII - PART FITTED
1 - Dismantling
a - Cutting
Cut 1 cm from the weld (see MR 400, Basic instruc-
tions for structural bodywork repair, 40A, General
information, Cutting tool for a structural compo-
nent: Use).
Remove the damaged part.
b - Grinding
Weaken the weld without removing it, using a straight
grinder fitted with a cutting disc.
Remove the remaining metal strips. Special tooling required
Car. 1786Levelling tool for bodywork
seal
Equipment required
safety strap(s)
121044
No. Description Type Thic-
kness
(mm)
(1) Roof Mild
steel0.75
120099
121622

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).
121623
121626
120077