torque RENAULT TWINGO RS 2009 2.G Transmission Workshop Manual

20A-1
CLUTCH
Clutch: Precautions for the repair
20A
Before removing the clutch, check:
-The direction of fitting for the clutch plate.
Before refitting the clutch, check:
-The flywheel friction track (no scratches or blue
stains),
-The crankshaft bearing (no sticking),
-The engine and gearbox seals (replace if necessary),
-The sliding action of the clutch plate on the output
shaft,
-The guide of the thrust bearing and clutch fork (no
wear or scratches).
During refitting:
Check the direction of the clutch plate.
Centre the clutch plate using the (Emb. 1518) or (Emb.
1780).
Gradually torque tighten the clutch pressure plate
bolts.
After refitting, check:
-The clutch play (for a cable operated vehicle),
-Bleeding of the hydraulic circuit (for vehicles with hy-
draulic controls).Special tooling required
Emb. 1518Set of clutch plate centr ing
mandrels
Emb. 1780Set of clutch plate centr ing
mandrels.
WARNING
To prevent the clutch from juddering or slipping, do
not grease the output shaft or the clutch plate hub.

20A-4
CLUTCH
Pressure plate - Disc: Removal - Refitting
D4F – D7F – K9K
20A
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).
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aLock the engine using tool (Mot. 582-01) (1) .
aRemove:
-the pressure plate bolts (2) ,
-the pressure plate and friction plate.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aDegrease the flywheel friction face.
aClean the clutch shaft splines. Special tooling required
Mot. 582-01Flywheel locking tool.
Emb. 1780Set of clutch plate centr ing
mandrels.
Tightening torquesm
clutch pressure plate
bolts (D4F and D7F
engines)20 Nm
clutch pressure plate
bolts (K9K engine)15 Nm
108799

20A-5
CLUTCH
Pressure plate - Disc: Removal - Refitting
D4F – D7F – K9K
20A
II - REFITTING OPERATION FOR PART
CONCERNED
aPosition the clutch plate, face (3) against the fly-
wheel, face (4) against the clutch pressure plate.
aPosition the clutch driven plate.aCentre the clutch plate using tool (Emb. 1780) (5) .
aRefit:
-the clutch pressure plate,
-the clutch pressure plate bolts by gradually tighten-
ing them in a radial pattern.
aTorque tighten the clutch pressure plate bolts
(D4F and D7F engines) (20 Nm).
aTorque tighten the clutch pressure plate bolts
(K9K engine) (15 Nm).
aRemove the (Emb. 1780) and (Mot. 582-01).
III - FINAL OPERATION.
aRefit the gearbox (see 21A, Manual gearbox, Man-
ual gearbox: Removal - Refitting, page 21A-24) .
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery). K9K
118975
D4F – D7F
108798
D4F – D7F
K9K

20A-6
CLUTCH
Pressure plate - Disc: Removal - Refitting
K4M
20A
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 bolts,
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery)
-the air filter box (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 engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the manual gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the (Mot. 1677) (1) .
aRemove:
-the clutch pressure plate bolts (2) ,
-the clutch pressure plate,
-the clutch plate. Special tooling required
Mot. 1677Flywheel locking tool.
Emb. 1780Set of clutch plate centr ing
mandrels.
Tightening torquesm
clutch pressure plate
bolts23 N.m
132329

20A-7
CLUTCH
Pressure plate - Disc: Removal - Refitting
K4M
20A
REFITTING
I - REFITTING PREPARATION OPERATION
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the flywheel friction face,
-the clutch shaft splines.
II - REFITTING OPERATION FOR PART
CONCERNED
aFit the clutch plate, with the face (3) to the clutch
pressure plate end.aCentre the clutch plate using the (Emb. 1780) (4) .
aRefit:
-the clutch pressure plate,
-the clutch pressure plate bolts by gradually tighten-
ing them in a radial pattern.
aTorque tighten the clutch pressure plate bolts (23
N.m).
aRemove the (Emb. 1780) and (Mot. 1677).
III - FINAL OPERATION.
aRefit:
-the manual gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) ,
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-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). WARNING
Do not grease the clutch shaft splines.
132331
132332

20A-9
CLUTCH
Clutch thrust bearing: Removal - Refitting
JH3 or JR5
20A
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 bolts,
-the engine undertray,
-the gearbox (see 21A, Manual gearbox, Manual
gearbox: Removal - Refitting, page 21A-24) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the clutch thrust bearing bolts (1) .aRemove the clutch thrust bearing (2) .
REFITTING
I - REFITTING PREPARATION OPERATION
a
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the clutch thrust bearing. Tightening torquesm
clutch thrust bearing
bolts (JH3)21 N.m
clutch thrust bearing
bolts (JR5)25 N.m
Note:
The clutch thrust bear ing cannot be separated from
the clutch slave cylinder.
108796
108797
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
WARNING
To avoid damaging the slave cylinder, do not coat
the gearbox output shaft with grease.
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.
Note:
To obtain optimum bleeding, pre-fill the clutch
thrust bearing when refitting the thrust bearing.

20A-10
CLUTCH
Clutch thrust bearing: Removal - Refitting
JH3 or JR5
20A
aTorque tighten the clutch thrust bearing bolts
(JH3) (21 N.m).
aTorque tighten the clutch thrust bearing bolts
(JR5) (25 N.m).
III - FINAL OPERATION.
aRefit the gearbox (see 21A, Manual gearbox, Man-
ual gearbox: Removal - Refitting, page 21A-24) .
aBleed the clutch control (see Clutch circuit: Bleed)
(37A, Mechanical component controls).
aRefit the engine undertray. JH3
JR5

21A-24
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and 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 battery (see Battery: Removal - Refitting)
(80A, Battery),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery).
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment).
aDisconnect the engine management computer con-
nectors.
aRemove:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aRemove the engine management computer mount-
ing.
aRemove the engine management computer wiring
harness nut from the engine management computer
mounting.
aRemove the engine management computer wiring
harness.
aRemove the engine management computer mount-
ing fitted with the engine management computer.aUnclip:
-the clutch hydraulic control pipe on the gearbox (1)
,
-the union (2) on the hydraulic tappet slave cylinder,
-the gearbox breather.
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).
aDrain the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (31A, Front axle com-
ponents),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting). Special tooling required
Mot. 1453Engine anchorage support
with m ultiple adjustments and
retaining str aps.
Equipment required
component jack
Tightening torquesm
lower gearbox bolts44 N.m
gearbox nuts and bolts44 N.m
gearbox upper bolts44 N.m
121410

21A-26
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and JH3 or JR5
21A
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the gearbox using a component jack,
-the gearbox stud nuts,
-the gearbox lower bolts.
aTorque tighten:
-the lower gearbox bolts (44 N.m),
-the gearbox nuts and bolts (44 N.m).
aRefit the upper gearbox bolts.
aTorque tighten the gearbox upper bolts (44 N.m).
aRefit the earth strap bolt on the gearbox.
aConnect:
-the reverse gear switch connector,
-the speed and position sensor connector.
aClip the gearbox controls into place.
II - FINAL OPERATION
aRefit:
-the subframe (see Front axle subframe: Removal
- Refitting) (31A, Front axle components),
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting).
aRemove the tool (Mot. 1453).
aRefit:
-the upstream strut of the catalytic converter by slid-
ing it upwards,
-the catalytic converter upstream strut bolt on the
catalytic converter.
aTighten the bolt and nut on the upstream strut of the
catalytic converter on the gearbox.
aRefit:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (31A, Front axle com-
ponents),
-the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging),-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aClip:
-the union onto the hydraulic tappet slave cylinder,
-the hydraulic clutch control pipe,
-the gearbox breather.
aBleed the clutch (see Clutch circuit: Bleed) (37A,
Mechanical component controls).
aRefit the engine management computer mounting
fitted with the engine management computer.
aFit the engine management computer wiring har-
ness.
aRefit the engine management computer wiring har-
ness nut on the engine management computer
mounting.
aFit the engine management computer mounting.
aRefit:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aConnect the engine management computer connec-
tors.
aRefit:
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
aFill up the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRefit:
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the battery (see Battery: Removal - Refitting)
(80A, Battery).

21A-27
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
D4F, and JB1 – D7F, and JB1
21A
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 battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery).
aRemove the air filter unit (see Air filter unit: Re-
moval - Refitting) (MR 411, 12A, Fuel mixture).
aRemove:
-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).aDisconnect the engine management computer con-
nectors.
aRemove:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aRemove the engine management computer mount-
ing.
aRemove the engine management computer wiring
harness nut from the engine management computer
mounting.
aRemove the engine management computer wiring
harness.
aRemove the engine management computer mount-
ing fitted with the engine management computer.
aUnclip:
-the clutch cable,
-the gearbox breather.
aRemove:
-the left-hand front wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection).
aDrain the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (MR 411, 31A, Front
axle components),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the starter (see Starter: Removal - Refitting) (MR
411, 16A, Starting - Charging). Special tooling required
Mot. 1453Engine anchorage support
with m ultiple adjustments and
retaining str aps.
Equipment required
component jack
Tightening torquesm
gearbox mountings44 Nm
D4F