torque RENAULT TWINGO RS 2009 2.G Transmission User Guide

21A-28
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
D4F, and JB1 – D7F, and JB1
21A
aFit the (Mot. 1453) :
-positioning it on the front wing opening stops and
on the headlight brackets,
-using the two engine lifting eyes to avoid the
« engine - gearbox » assembly tilting too much,
-making sure the tool is strapped to the vehicle.
aRemove:
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Re-
moval - Refitting) (MR 411, 19D, Engine mount-
ing),
-the subframe (see Front axle subframe: Removal
- Refitting) (MR 411, 31A, Front axle component).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the reverse gear switch connector.
aRemove:
-the earth strap bolt on the gearbox,
-the gearbox upper bolts,
-the engine speed and position sensor (see Crank-
shaft position sensor: Removal - Refitting) (MR
411, 17B, Petrol injection).
-the gearbox lower bolts,
-the flywheel protection plate bolts,
-the flywheel protection plate,
-the gearbox stud nuts,
-the gearbox using a component jack.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the gearbox using a component jack.
-the gearbox mountings.
aTorque tighten the gearbox mountings (44 Nm).
aRefit:
-the engine speed and position sensor (see Crank-
shaft position sensor: Removal - Refitting) (MR
411, 17B, Petrol injection),
-the earth strap bolt on the gearbox.
aConnect the reverse gear switch connector.
II - FINAL OPERATION.
aRefit:
-the subframe (see Front axle subframe: Removal
- Refitting) (MR 411, 31A, Front axle compo-
nents),
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Re-
moval - Refitting) (MR 411, 19D, Engine mount-
ing).
aRemove the (Mot. 1453).
aRefit:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (MR 411, 31A, Front
axle components),
-the starter (see Starter: Removal - Refitting) (MR
411, 16A, Starting - Charging),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres).
aClip:
-the clutch cable,
-the gearbox breather.
121415

21A-30
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).aRemove:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) ,
-the differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-38) (21A, Manual gearbox),
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the “engine - gearbox” assembly from
theusing a workshop hoist.
aDisconnect the TDC sensor connector (1) . Equipment required
workshop hoist
Tightening torquesm
manual gearbox nuts
and bolts44 N.m
earth strap bolt on the
gearbox44 N.m
support bolts for the
suspended engine
mounting on the gear-
box62 N.m
132319

21A-32
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
aRemove:
-the bolts (8) and the nuts (9) from the manual gear-
box,
-the manual gearbox.
REFITTING
I - REFITTING PREPARATION OPERATION
a
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the manual gearbox.
aTorque tighten the manual gearbox nuts and bolts
(44 N.m).
132325
132324132326
WARNING
Never operate the system when the slave cylin-
der is removed (even if it is connected to the
clutch pedal). There is a risk that the hydraulic
piston and the sla ve cylinder stop will be ejected.
WARNING
To avoid damaging the slave cylinder, do not coat
the gearbox output shaft with grease.
WARNING
Do not grease the clutch shaft splines.

21A-33
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
aFit the engine wiring.
aRefit:
-the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging),
-the bolts of the engine wiring channel,
-the earth strap bolt on the gearbox.
aTorque tighten the earth strap bolt on the gearbox
(44 N.m).
aConnect the reverse gear switch connector.
aClip on the reverse gear switch.
aRefit the suspended engine mounting support on the
gearbox.
aTorque tighten the support bolts for the suspend-
ed engine mounting on the gearbox (62 N.m).
aConnect the TDC sensor connector.
aRefit the engine - gearbox assembly on the.
III - FINAL OPERATION
aRefit:
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the differential output seals (see 21A, Manual
gearbox, Differential output seal: Removal - Re-
fitting, page 21A-38) (21A, Manual gearbox),
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) .
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the air filter unit (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aRefill:
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).
aRefit the engine undertray.

21A-44
MANUAL GEARBOX
Reverse gear switch: Removal - Refitting
JB1 or JH1 or JH3 or JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection).
aRemove the engine undertray.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the connector (1) from the reverse gear
switch.aRemove the reverse gear switch using the tool (Bvi.
1934) (2) .
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aApply some SILICONE ADHESIVE SEALANT (see
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products) to the threading of
the reverse gear switch.
aRefit the reverse gear switch using the (Bvi. 1934).
aTorque tighten the reverse gear switch (23 N.m).
aConnect the reverse gear switch connector.
II - FINAL OPERATION
aFill the gearbox (see 21A, Manual gearbox, Manu-
al gearbox oils: Draining - Filling, page 21A-2) .
aRefit the engine undertray.
aRefit:
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection), Special tooling required
Bvi. 1934Socket for removing/refitting
reverse gear switch
Tightening torquesm
reverse gear switch23 N.m
132082
144801
Note:
Seal the housing of the reverse gear switch while
replacing the par t.

21B-3
SEQUENTIAL GEARBOX
Sequential gearbox oil: Draining - Filling
JH1
21B
Oil capacity
DRAINING
I - DRAINING PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray bolts,
-the engine undertray.
II - DRAINING OPERATION
aFit a oil recovery tray under the gearbox.aRemove:
-the gearbox drain plug (1) using the tool (Mot.
1018),
-the drain plug seal.
aLet the oil run into the oil recovery tray.
FILLING
I - FILLING PREPARATION OPERATION
aAlways replace the manual gearbox drain plug seal. Special tooling required
Mot. 10188 mm square engine drain
plug spanner.
Equipment required
oil recovery tray
Tightening torquesm
drain plug25 N.m
Gearbox type Oil capacity (in litres)
JH1 2.8
JA32.8
JA52.5
18749

21B-4
SEQUENTIAL GEARBOX
Sequential gearbox oil: Draining - Filling
JH1
21B
aPosition the slot (2) of the new seal towards the
drain plug.
aRefit the drain plug fitted with its new seal.
aTorque tighten the drain plug (25 N.m).
II - FILLING OPERATION
aRemove the filler plug (3) .aFill the gearbox using a syringe containing recom-
mended oil (see 21A, Manual gearbox, Manual
gearbox oil: Specifications, page 21A-1) (Techni-
cal Note 6012A, 04A, Lubricants) until the oil over-
flows out of the filler cap hole.
aRefit the filler plug.
III - FINAL OPERATION
aWipe any oil run-off with a cloth.
aRemove the oil recovery tray.
aRefit the engine undertray.
113764
18749
92081

21B-11
SEQUENTIAL GEARBOX
Electro-hydraulic unit: Removal - Refitting
D4F, and JH1
21B
The electro-hydraulic unit comprises the pump assem-
bly and the actuator module.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection).
aDetach from the petrol injection computer mounting:
-the cooling hose,
-the sequential gearbox computer wiring harness,
-the petrol injection computer wiring harness,
-the battery wiring harness. Special tooling required
Mot. 1390Suppor t for removal - refitting
of engine - gearbox assembly
Equipment required
Diagnostic tool
Tightening torquesm
left-hand suspended
engine mounting bolts21 N.m
left-hand suspended
engine mounting rubber
pad bolts62 N.m
left-hand suspended
engine mounting rubber
pad nut105 N.m
Note:
When replacing the electric pump assembly, always
replace the control relay.
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 21B, Sequential gearbox, Sequential
gearbox: Precautions for the repair, page 21B-1)
.

21B-16
SEQUENTIAL GEARBOX
Electro-hydraulic unit: Removal - Refitting
D4F, and JH1
21B
aIt is essential to replace the electro-hydraulic unit
seal.
aPlace the actuator module selector shaft in a raised
and locked position.
II - REFITTING OPERATION FOR PART
CONCERNED
aFit:
-the new electro-hydraulic unit seal,
-the electro-hydraulic unit.
aRefit:
-the sequential gearbox lifting eye on the sequential
gearbox,
-the breather pipe on the sequential gearbox.
-the electro-hydraulic unit nuts,
-the electro-hydraulic unit bolts.
aConnect the sequential gearbox speed sensor con-
nector.
aAttach the breather pipe:
-to the cooling hose,
-to the sequential gearbox lifting eye.aPress on the selector shaft with a screwdriver to clip
the sequential gearbox selector shaft to the actuator
module.
aRefit the clutch stay cable to the clutch fork.
aConnect the electro-hydraulic unit connector by
moving the lock.
III - FINAL OPERATION
aRefit:
-the selector shaft cover,
-the selector shaft cover bolt.
aFit the left-hand suspended mounting on the body.
aFit the left-hand suspended engine mounting bolts
without tightening them.
aTorque tighten the left-hand suspended engine
mounting bolts (21 N.m).
aRaise the sequential gearbox to its original position.
aFit the left-hand suspended engine mounting rubber
pad.
aFit the left-hand suspended engine mounting rubber
pad bolts without tightening them.
aTorque tighten the left-hand suspended engine
mounting rubber pad bolts ( 62 N.m).
aFit the left-hand suspended engine mounting rubber
pad nut without tightening it.
aTorque tighten the left-hand suspended engine
mounting rubber pad nut (105 N.m ).
17970
17970

21B-18
SEQUENTIAL GEARBOX
Pump assembly: Removal - Refitting
D4F, and JH1
21B
The electro-hydraulic unit comprises the pump assem-
bly and the actuator module.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Re-
fitting, page 21B-11) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the supply connector from the pump as-
sembly pump.
aDetach the pump assembly pump supply connector
from the electro-hydraulic unit connector mounting. Special tooling required
Ms. 583Pipe clamps .
Equipment required
Diagnostic tool
Tightening torquesm
high pressure pipe
unions14 N.m
Note:
When replacing the electric pump assembly, always
replace the control relay.
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 21B, Sequential gearbox, Sequential
gearbox: Precautions for the repair, page 21B-1)
.
Note:
To discharge the accumulator and deactivate the
pump assembly pump, (see Fault finding -
Replacement of components) (21B, Sequential
gearbox).