warning 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-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.

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.

21B-1
SEQUENTIAL GEARBOX
Sequential gearbox: Precautions for the repair
D4F, and JH1
21B
I - SEQUENTIAL GEARBOX
II - SEQUENTIAL GEARBOX COMPUTER
To disconnect the computer, switch off the ignition and
wait for 1 minute.
III - ELECTRO-HYDRAULIC UNIT
Discharge the pressure accumulator using the Diag-
nostic tool before any operation on the electro-hy-
draulic unit.
Be careful not to twist the high pressure pipes when re-
moving the electro-hydraulic unit.
IV - GEAR SELECTION SENSOREquipment required
Diagnostic tool
IMPORTANT
Before any operation on the sequential system, dis-
charge the accumulator using the Diagnostic tool.
WARNING
If any operation is carried out on the electro-hydrau-
lic unit, it is essential to clean the unit using a clean-
ing product and compressed air.
Never leave the circuit open and never use a high
pressure cleaner.
WARNING
After the accumulator has been fully filled (15 sec-
onds after the ignition has been switched on): the
oil level is at the MINIMUM mark.
WARNING
To remove the gear selection sensor it is essential
that you shift to first gear before removal.

21B-7
SEQUENTIAL GEARBOX
Pressure accumulator: Removal - Refitting
D4F, and JH1
21B
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a
aRemove the pressure accumulator (8) from the actu-
ator module using the (Mot. 445) (9) .
REFITTING
I - REFITTING PREPARATION OPERATION
aIf replacing the pressure accumulator, affix a safety
label to the accumulator.
aIt is essential to replace the pressure accumulator
seal.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the pressure accumulator onto the actuator
module using the (Mot. 445).
III - FINAL OPERATION
aClip the pump assembly supply connector onto the
electro-hydraulic unit connector mounting.
aConnect the pump assembly supply connector.aRefit:
-the sequential gearbox lifting eye on the sequential
gearbox,
-the sequential gearbox lifting eye nut,
-the breather pipe on the sequential gearbox.
aAttach the breather pipe:
-to the cooling hose,
-to the sequential gearbox lifting eye.
aFit:
-the petrol injection computer support,
-the engine wiring harness on the petrol injection
computer mounting.
aRefit:
-the petrol injection computer mounting bolts,
-the engine wiring harness nut on the petrol injec-
tion computer mounting,
-the petrol injection computer mounting nut.
aClip onto the petrol injection computer mounting:
-the battery wiring harness,
-the petrol injection computer wiring harness,
-the sequential gearbox computer wiring harness,
-the cooling hose.
aRefit:
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery).
aFill the electric pump assembly reservoir with oil
(see Sequential gearbox oil: Specifications)
(Technical Note 6012, 04A, Lubricants) to between
32 and 38 mm above the MIN mark.
122315
Note:
Prepare for oil to flow out of the electro-hydraulic
unit.
WARNING
After the accumulator has been fully filled (15
seconds after the ignition has been switched on):
the oil level is at the MINIMUM mark.

21B-10
SEQUENTIAL GEARBOX
Pump assembly reservoir: Removal - Refitting
D4F, and JH1
21B
REFITTING
I - REFITTING PREPARATION OPERATION
aIn the event of replacement, refit:
-the low pressure hose,
-the low pressure hose clip.
aIt is essential to replace the pump assembly reser-
voir seal on the pump inlet.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the pump assembly reservoir,
-the pump assembly reservoir bolts.
III - FINAL OPERATION
aAssemble:
-the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Re-
fitting, page 21B-11) ,
aRemove
-the pump assembly on the electro-hydraulic unit
(see 21B, Sequential gearbox, Pump assembly:
Removal - Refitting, page 21B-18) ,
-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),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery).aFill the electric pump assembly reservoir with oil
(see Sequential gearbox oil: Specifications)
(Technical Note 6012, 04A, Lubricants) to between
32 and 38 mm above the MIN mark.
aCarry out the necessary operations using the Diag-
nostic tool (see Fault finding - Replacement of
components) (MR 413, 21B, Sequential gearbox). WARNING
After the accumulator has been fully filled (15
seconds after the ignition has been switched on):
the oil level is at the MINIMUM mark.

21B-17
SEQUENTIAL GEARBOX
Electro-hydraulic unit: Removal - Refitting
D4F, and JH1
21B
aRefit:
-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),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting).
Refit.
aFit:
-the petrol injection computer support,
-the engine wiring harness on the petrol injection
computer mounting.
aRefit:
-the petrol injection computer mounting bolts,
-the engine wiring harness nut on the petrol injec-
tion computer mounting,
-the petrol injection computer mounting nut.
aClip onto the petrol injection computer mounting:
-the battery wiring harness,
-the petrol injection computer wiring harness,
-the sequential gearbox computer wiring harness,
-the cooling hose.
aRefit:
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery).
aFill the electric pump assembly reservoir with oil
(see Sequential gearbox oil: Specifications)
(Technical Note 6012, 04A, Lubricants) to between
32 and 38 mm above the MIN mark.aIf replacing the electro-hydraulic unit, carry out the
necessary operations using the Diagnostic tool
(see Fault finding - Replacement of components)
(MR 413, 21B, Sequential gearbox).
WARNING
After the accumulator has been fully filled (15
seconds after the ignition has been switched on):
the oil level is at the MINIMUM mark.

21B-19
SEQUENTIAL GEARBOX
Pump assembly: Removal - Refitting
D4F, and JH1
21B
aPosition the (Ms. 583) on the reservoir low pressure
return hose (1) .
aRemove the clip (2) from the reservoir return hose.
aDisconnect the reservoir low pressure return hose
(1) from the actuator module.
aRemove:
-the clutch stay high pressure supply pipe bracket
bolt (3) ,
-the actuator module high pressure supply pipe by
pressing on the unions (4) ,
-the clutch stay high pressure supply pipe by press-
ing on the unions (5) ,
-the pump assembly from the actuator module.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aFit:
-the clutch stay high pressure supply pipe,
-the actuator module high pressure supply pipe.
aFit the high pressure pipe unions, without tightening
them.aConnect the reservoir low pressure return hose to
the actuator module.
aRefit the reservoir return hose clip on the actuator
module.
aRemove the (Ms. 583) from the reservoir low pres-
sure return hose.
aClip the pump assembly supply connector onto the
electro-hydraulic unit connector mounting.
aConnect the pump assembly supply connector.
II - FINAL OPERATION
aRefit the electro-hydraulic unit (see 21B, Sequential
gearbox, Electro-hydraulic unit: Removal - Refit-
ting, page 21B-11) .
aTorque tighten the high pressure pipe unions (14
N.m).
aRefit:
-the clutch stay high pressure supply pipe bracket
bolt,
-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 rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-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 sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aFill the electric pump assembly reservoir with oil
(see Sequential gearbox oil: Specifications)
(Technical Note 6012, 04A, Lubricants) to between
32 and 38 mm above the MIN mark.
122171
Note:
Prepare for oil to flow out of the electro-hydraulic
unit.
WARNING
After the accumulator has been fully filled (15
seconds after the ignition has been switched on):
the oil level is at the MINIMUM mark.

21B-26
SEQUENTIAL GEARBOX
Solenoid valves: Removal - Refitting
D4F, and JH1
21B
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 ).
aRefit:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (MR 411,
19D, Engine mounting),
-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).
3 - Refitting all solenoid valves
aFit:
-the petrol injection computer support,
-the engine wiring harness on the petrol injection
computer mounting.
aRefit:
-the petrol injection computer mounting bolts,
-the engine wiring harness nut on the petrol injec-
tion computer mounting,
-the petrol injection computer mounting nut.
aClip onto the petrol injection computer mounting:
-the battery wiring harness,
-the petrol injection computer wiring harness,
-the sequential gearbox computer wiring harness,
-the cooling hose.
aRefit:
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (MR 411, 17B,
Petrol injection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (MR 411, 80A, Battery),
-the sequential gearbox computer (see 21B, Se-
quential gearbox, Sequential gearbox convert-
er: Removal - Refitting, page 21B-47) ,
-the battery (see Battery: Removal - Refitting)
(MR 411, 80A, Battery).aFill the electric pump assembly reservoir with oil
(see Sequential gearbox oil: Specifications)
(Technical Note 6012, 04A, Lubricants) to between
32 and 38 mm above the MIN mark.
aCarry out the necessary operations using the Diag-
nostic tool (see Fault finding - Replacement of
components) (MR 413, 21B, Sequential gearbox). WARNING
After the accumulator has been fully filled (15
seconds after the ignition has been switched on):
the oil level is at the MINIMUM mark.