Renault Twingo 2007, Twingo 2008, Twingo 2009, Twingo 2010, Twingo 2011 User Manual

0

General vehicle information

01A

01C

01D

02A

03B

04B

04E

VEHICLE MECHANICAL SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

MECHANICAL INTRODUCTION

LIFTING EQUIPMENT

COLLISION

CONSUMABLES - PRODUCTS

PAINT

NOVEMBER 2009 EDITION ANGLAISE

"The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are

constructed".

X44

© Renault s.a.s 2007

All rights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part reference

numbering system is forbidden without the prior written authority of Renault.

TWINGO - Chapitre 0ContentsPages

TWINGO - Chapitre 0

Contents

Pages

01A VEHICLE MECHANICAL SPECIFICATIONS

Vehicle: Specifications 01A-1

01C VEHICLE BODYWORK SPECIFICATIONS

Vehicle: Identification 01C-1
Vehicle panel gaps:

Adjustment value 01C-3

01D MECHANICAL INTRODUCTION

Vehicle: Precautions for the
repair 01D-1

Tightening torques: General
information 01D-3

03B COLLISION

Vehicle involved in a side
impact: Description 03B-7

Vehicle involved in a rear
impact: Description 03B-10

04B CONSUMABLES - PRODUCTS

Vehicle: Parts and
consumables for the repair 04B-1

04E PAINT

Anti-corrosion protection
product: Description 04E-1

02A LIFTING EQUIPMENT

Vehicle: Towing and lifting 02A-1

03B COLLISION

Vehicle involved in an
impact: Impact fault finding 03B-1

Vehicle involved in a frontal
impact: Description 03B-4

VEHICLE MECHANICAL SPECIFICATIONS

Vehicle: Specifications

01A

Dimensions in metres

A 0.710 / 0.714 (RS)
B 2.367
C 0.525
D 3.602
E 1.400 / 1.414 (GT, RS)
F 1.470 (unladen)
G 1.386 / 1.400 (GT) / 1.430 (RS)
H 1.655

122555

01A-1

VEHICLE MECHANICAL SPECIFICATIONS

Vehicle: Specifications

Engine type Engine suf-fixCubic

capacity(cc)

772

D4F

1149

780
782 309 EURO 5

D7F 800 JB1 520

Gearbox Gearbox

suffix

521
523

JB1

JH1

JH3

524
525 EURO 5
020 EURO 4
021 EURO 5
169 EURO 4

01A

Emissions
standard

EURO 4

K4M 854 1598 JR5 176

K9K

718

1461

740 JH3 166

JR5 193

EURO 4

01A-2

VEHICLE BODYWORK SPECIFICATIONS

Vehicle: Identification

I - LOCATION OF VEHICLE IDENTIFICATION
PLATE

01C

III - DETAILED VIEW OF THE VEHICLE
IDENTIFICATION PLATE

Plate (A)

120451

II - LOCATION OF THE VEHICLE IDENTIFICATION
NUMBER

120452

19031

(1) Vehicle type and type number;

this information also appears on
marking (B)

(2) MPAW (Vehicle's Maximum Per-

missible All-up Weight)

(3) GTW (Gross train weight, vehi-

cle under load with trailer)

(4) Maximum permissible front axle

load

(5) Maximum permissible rear axle

load
(6) Technical vehicle specifications
(7) Paintwork reference number
(8) Equipment level
(9) Vehicle type
(10) Upholstery code
(11) Additional equipment details
(12) Production number
(13) Interior trim code

01C-1

VEHICLE BODYWORK SPECIFICATIONS

Vehicle: Identification

IV - COLD-MARKING OF THE BODY

Marking (B)

01C

121197

Note:
If the complete body is being replaced, it must be

marked in compliance with the current regulations.

01C-2

VEHICLE BODYWORK SPECIFICATIONS

Vehicle panel gaps: Adjustment value

01C

WARNING

The clearance values are given for information pur­poses.

When adjusting clearances, certain rules have to be
followed:

- maintain symmetry with respect to the opposite
side,

- ensure the flush fitting is correct,

- check correct operation of the opening, and water/
air-tightness.

All values are given in millimetres.

Section 1

120453

120385

(X1) = 3.5 ±±±± 1.5

01C-3

VEHICLE BODYWORK SPECIFICATIONS

Section 2

Vehicle panel gaps: Adjustment value

Section 4

01C

(X2) = 2 ±±±± 1.5

Section 3

120382

120383

(X4) = 3.5 ±±±± 1.5

Section 5

(X3) = 3 ±±±± 1.5

120381

120384

(X5) = 2 ±±±± 1.3

01C-4

VEHICLE BODYWORK SPECIFICATIONS

Section 6

Vehicle panel gaps: Adjustment value

Section 8

01C

(X6) = 2 ±±±± 1.3

Section 7

120386

120388

(X8) = 2.5 ±±±± 1.3

Section 9

(X7) = 0 + 1/- 0

120380

120392

= 4.2 ±±±± 1

01C-5

VEHICLE BODYWORK SPECIFICATIONS

Section 10

Vehicle panel gaps: Adjustment value

Section 12

01C

(X10) = 2 ±±±± 1.5

Section 11

120387

120393

(X12) = 4 ±±±± 1.5

Section 13

(X11) = 5 ±±±± 2

120390

120394

(X13) = 4 ±±±± 2.3

01C-6

VEHICLE BODYWORK SPECIFICATIONS

Vehicle panel gaps: Adjustment value

Section 14 (X14) = 5.5 ±±±± 1.5

01C

120389

01C-7

120454

VEHICLE BODYWORK SPECIFICATIONS

Section 15

Vehicle panel gaps: Adjustment value

Section 17

01C

(X15) = 5.3 ±±±± 1

Section 16

120395

120397

(X17) = 1.5 ±±±± 1

Section 18

(X16) = 4.5 ±±±± 1.5

120396

120398

(X18) = 4 ±±±± 1.8

01C-8

VEHICLE BODYWORK SPECIFICATIONS

Section 19

Vehicle panel gaps: Adjustment value

Section 21

01C

(X19) = 1.5 ±±±± 1.5

Section 20

120400

120399

(X21) = 6 ±±±± 1.8

Section 22

(X20) = 0 + 1/- 0

120401

120391

(X22) = 2.5 ±±±± 1

01C-9

MECHANICAL INTRODUCTION

Vehicle: Precautions for the repair

GENERAL INFORMATION

All information contained in these manuals is intended
exclusively for automotive industry professionals.

The documentation is intended to cover all vehicles in
the RENAULT range throughout the world, but may not
cover equipment designed for use in specific countries.

The procedures and fault finding procedures recom­mended and described in this manual have been de­signed by automotive industry repair professionals.

1 - General recommendations

Observe basic principles of vehicle repair.
The quality of repair depends first and foremost on the

care exercised by the person in carrying it out.
To ensure good repair:

- protect the sensitive areas of the vehicle (seats,
steering wheel, wings, etc.),

-unless otherwise indicated, all repairs must be done
with the ignition off,

01D

- protect the accessories and timing belts, the electrical
accessories (starter, blanking cover, electric power

assisted steering pump) and the mating face to pre­vent diesel fuel spilling onto the clutch friction plate.

The design quality of our vehicles demands that noth­ing is left to chance in making a good repair, and it is

essential to refit parts or components exactly as they
were originally (for instance: heat shields, wiring rout­ing, pipe routing, particularly in the area of the exhaust
pipe).

Do not blow away asbestos particles or dust (brakes,
clutch, etc.), vacuum them up or clean the component

with a cleaning agent (such as a brake cleaning prod­uct).

Use professional products and apply them with care,
for example do not apply too much sealing paste to the

sealing surface.
Exhaust gases (petrol and diesel) are pollutants. Oper-

ate engines with care and always use exhaust gas ex­tractors.

- when welding on the vehicle, it is advisable to remove
or disconnect components near the repair area that

could be affected by the heat,

- use recommended professional products and original
parts,

- observe the tightening torques,

- replace roll pins, self-locking or bonded nuts or bolts
every time they are removed,

- take care with electrical and electronic components
which cannot withstand excess voltage and improper
handling; replace any electrical and electronic com­ponents which have experienced a voltage drop,

- make sure that the connectors are correctly clipped,

- do not pull on the wiring,

- check for the sealing plugs on the connectors,

- Do not splash any liquid, regardless of its type (oil,
cleaner, etc.), on the electric and electronic compo­nents (computers, sensors, etc.)

- do not just replace parts one after the other, carry out
detailed fault finding beforehand,

-carry out a final check before returning the vehicle to
the customer (set the clock, check the alarm opera­tion, check the lights and indicators etc.),

- clean and degrease the sections to be bonded
(threads, stub axle splines) to ensure proper adher­ence,

Ensure that there is no risk of a short circuit occurring
when the electrical connections are reconnected (e.g.

starter, alternator, etc.). Some points need greasing,
others do not, therefore particular attention should be
paid during refitting operations to ensure that they work
properly under all conditions.

2 - Special tooling - ease of use

The repair procedures have been designed using spe­cial tools; they must therefore be carried out using

these tools to ensure a high degree of working safety
and quality of repair.

The equipment we have approved has undergone
careful research and testing, and must be used and

maintained with care.

3 - Reliability - updating

New repair procedures are constantly being developed
in the interests of repair quality, either with new prod-

ucts (emission control, injection, electronics, etc.), or in
fault finding. Be sure to consult the Workshop Repair

Manuals or Technical Notes or fault finding summaries
before any servicing operation.

Since vehicle specifications are subject to change dur­ing their commercial life, it is essential to check wheth­er there are any updated Technical Notes when
seeking information.

01D-1

MECHANICAL INTRODUCTION

Vehicle: Precautions for the repair

4 - Safety

Operations on certain equipment and certain parts (for
instance: spring-shock absorber assembly, automatic
transmission, brake system, ABS, airbag, common rail
diesel injection, LPG, etc.) require particular attention
to be paid to safety, cleanliness and care.

The safety symbol used in this manual indicates that
special attention must be paid to the procedure or the
tightening torque values.

Working safely:

- use suitable tools which are in good condition (use of
« multi-purpose » tools, such as adjustable pliers,
etc., should be avoided wherever possible),

- use supports and adopt a correct posture when per­forming heavy work or raising loads,

- make sure that the procedure used is not dangerous,

01D

5 - Conclusion

The procedures contained in this document merit your
attention. Please read them carefully in order to reduce
the risk of injury, and avoid using incorrect procedures
that could damage the vehicle or make it dangerous in
use.

Following the recommended procedures will help you
to provide a quality of service which will ensure the ve­hicles achieve the highest levels of performance and
reliability.

Maintenance and repair operations must be carried out
under the proper conditions to ensure that our vehicles
run safely and reliably.

- Do not wear any jewellery or other small objects dur­ing an operation,

- use personal protection (gloves, safety glasses, work
shoes, masks, skin barrier creams, etc.),

- always follow the safety instructions associated with
the operation to be performed,

- do not smoke when working on vehicles,

- use smoke extractors (welding, exhaust gases, etc.),

- do not use harmful products in unventilated rooms,

- do not overstrain yourself or attempt inappropriate
work operations,

- use axle stands when working under a vehicle raised
on a jack,

- do not ingest any chemicals (brake fluid, coolant,
etc.),

- do not open the cooling circuit when it is hot and pres­surised,

- take care with components that are liable to start up
suddenly (engine cooling fan, etc.).

Respecting the environment:

-do not allow waste refrigerants to escape into the at­mosphere,

- do not dispose of waste vehicle fluids (oil, brake fluid,
etc.) in drains,

- do not burn discarded products (tyres, etc.).

01D-2

MECHANICAL INTRODUCTION

Tightening torques: General information

I - TABLE OF STANDARD TORQUES

Fastenings Standard

tightening

Diameter Property

class

M6 8.8 10
M8 8.8 25
M10 8.8 50

M10 10.9 62
M12 10.9 105

M14 10.9 180
M16 10.9 280

torque
(N.m)

01D

The property class is indicated on the bolt (1) or (2) .

II - FUNCTION OF A BOLTED ASSEMBLY

The bolting system connects parts of an assembly to
prevent their separation or sliding when submitted to
exterior forces.

Exterior forces

M18 10.9 400

Special notes on electrical earths

Fastenings Standard

tightening

Diameter

M6 8
M8 21
M10 44

torque
(N.m)

120737

The assembly is submitted to forces that are:

- static and / or dynamic,

- simple (e.g. simple traction),

- multiple (traction + flexion + torsion).

120736

01D-3

MECHANICAL INTRODUCTION

Tightening torques: General information

Creating tension (or preload) F0

01D

Customer complaints resulting from incorrect tighten­ing may be, following assembly, a safety issue (fire,
loss of control of the vehicle etc.), an immobilising fault
or a noise.

III - TIGHTENING PROCEDURES

The two controlled tightening procedures adapted to
automotive repairs because of their low cost and sim­ple operation are torque tightening and angle tighten­ing (also called torque and angle).

1 - Torque tightening

This is the most commonly used procedure. Is consists
of tightening until a given resisting torque is reached,
known as tightening torque.

The tightening torque is distributed in a large part as
friction torque (under the head and in the thread) and in
a small part as useful torque (to create the tension).

120738

The assembly is held together by the tension created in
the bolt when it is tightened.

A reliable assembly is only possible if the correct ten­sion is used:

- insufficient tension: risk of loosening,

- too much tension: risk of deformation of the parts to
be assembled, or shearing of the bolt.

This practise spreads the tension significantly due to
the variation in the friction coefficients from one assem­bly to another and the uncertainty of the tightening pro­cedures and methods.

2 - Angle tightening

The principle consists of putting the parts of the assem­bly in contact using a mating torque (approximately 25
to 30% of the final torque) then to tighten to a deter­mined angle.

This method, which is not dependent on the friction of
the tightened assembly, gives more precise results
than torque tightening.

IV - OBSERVING THE TIGHTENING TORQUES AND
ANGLES

Bolted assemblies whose tightening torques and an­gles are explicitly specified in the removal / refitting
procedures must be observed using the appropriate
tools (torque wrench, angle measuring disc). Failure to
observe this can lead to safety risks, immobilising
faults or unwanted noises.

(3) Bolt
(4) Assembled components
(5) Extension of the bolt
(6) Non-tightened assembly
(7) Tightened assembly

(X1) compression of the assembly
(Fo) tension
(C) tightening torque

120739

For other bolted assemblies, non-measured tightening
(using standard spanners) is acceptable. Neverthe­less, the corresponding tightening torque is indicated in
the table of standard tightening torques.

V - RECOMMENDED TIGHTENING TOOLS

For measured tightening, the repairer must have avail­able torque wrenches to tighten from 4 to 400 N.m as
well as an angle measuring disc.

The torque wrenches used may be click type or elec­tronic.

01D-4

MECHANICAL INTRODUCTION

Tightening torques: General information

For example:

-1 torque wrench 4 - 40 N.m,

-1 torque wrench 20 - 100 N.m,

-1 torque wrench 80 - 400 N.m,

-1 angle measurement disc.

The torque wrenches used must comply with the ISO
6789 standard. They must be calibrated regularly fol­lowing the supplier's recommendations using the ap­propriate procedures.

VI - PRECAUTIONS WHEN USING A CLICK TYPE
TORQUE WRENCH

A click type torque wrench is a manual tightening tool.
The trigger mechanism causes a break or disengage­ment of the wrench past a force threshold.

This threshold depends on the setting of the wrench
but also depends on the way the wrench is handled.

01D

120741

- Pull the wrench gently and steadily, without applying
any torsion. Excessive tightening speed as well as jerk­iness are major causes of overtightening. Any torsion
applied to the wrench will alter the trigger threshold.

- Hold the wrench on the bolt using a minimum of effort.
Any effort applied to the wrench head will alter the trig-

ger threshold.

When used following best practises, the accuracy of
the tightness when using a click type torque wrench is

± 15%.
The instructions to be observed are:

120742

- Apply the tightening effort perpendicular to the mount­ing observing a tolerance of ± 15˚ relative to the per-
pendicularity. If the wrench is not perpendicular to the
mounting axis, this will result in insufficient tightening.

120740

(6) lever arm

- Place the hand in the centre of the handle. An incor-

rectly positioned hand on the handle will alter the trig­ger threshold.

- Stop tightening as soon as the wrench is triggered.
Continued tightening after the wrench is triggered will
lead to overtightening.

01D-5

MECHANICAL INTRODUCTION

Tightening torques: General information

It is advisable to handle the wrench with care and to
stop tightening when the required value is displayed on
the wrench.

01D

120743

If the length of the wrench is modified (extending the
handle, adapting an end piece) it is essential to recali­brate the wrench to its new configuration.

Modifying the length of the wrench will modify its trigger
threshold.

Use the formula: C1 = CO x L2 / (L1+L2)

- CO: torque to apply,

- C1: adjustment torque to be displayed on the wrench,

- L1: length of the extension,

- L2: length of the wrench.

Unless there are special instructions in the repair meth­od, a universal joint (CARDAN joint type) should be
used for measured tightening. Using a universal joint
will result in a difference between the set torque of the
wrench and the actual torque applied.

Before storing the wrench, loosen the adjustment
spring completely. A wrench stored with a spring under
tension will lose its tightening accuracy.

VII - PRECAUTIONS WHEN USING ELECTRONIC
TORQUE WRENCHES

An electronic torque wrench is a manual tightening
tool. The tightening torque and, depending on the mod­el, the angle is read directly.

When used following best practises, the accuracy of
the tightness when using an electronic torque wrench
is ± 5%.

Electronic torque wrenches are not affected by the po­sition of the operator's hand.

01D-6

LIFTING EQUIPMENT

Vehicle: Towing and lifting

Equipment required

Diagnostic tool
safety strap(s)

I - TOWING

WARNING

See the current towing regulations in each country.
Never use the drive shafts as attachment points.
The towing points may only be used for towing on

the road.
Never use the towing points for removing the vehi-

cle from a ditch or to lift the vehicle, either directly
or indirectly.

02A

1 - Position of front attachment point

Screw in and lock the towing ring before towing.
Vehicles fitted with automatic transmission:

- The vehicle should preferably be transpor ted on a

platform or towed b y lifting the front wheels. As an
exception, the vehicle may be towed with the
wheels on the ground but at a speed below 12

mph (20km/h) and over a maximum distance of
18 miles (30 kms) (with the gear lever in neutral).

Vehicles fitted with Renault Card:

- If the vehicle battery is flat, the steering column

remains locked. In this case, fit a new battery or
connect to an electrical source to lock the airbag
computer using the Diagnostic tool (see Airbag
and pretensioners: Precautions for the repair)
(88C, Airbag and pretensioners), which unlocks
the steering column.

-If it is not possible to lock the airbag computer, the

front of the vehicle must be lifted.

120735

2 - Position of rear attachment point

II - LIFTING BY TROLLEY JACK

IMPORTANT

To prevent any accidents, the trolley jack must only
be used to lift and/or move the vehicle. The vehicle

height must be maintained with axle stands which
are strong enough to support the weight of the vehi­cle.

02A-1

120450

LIFTING EQUIPMENT

Vehicle: Towing and lifting

WARNING

To avoid any damage to the original protection, use
equipment fitted with rubber pads to prevent the
equipment coming into direct contact with the vehi­cle.

To avoid any damage to the axle assemblies, the
vehicle must not be raised using the front suspen­sion arms for support or under the rear axle.

02A

To mount the vehicle onto axle stands, lift the entire ve­hicle on one side and the axle stands must be placed
under zones (1) and (2) designed for positioning the
tool kit jack.

III - LIFTING ON A LIFT

1 - Safety advice reminder

120614

14894

To remove heavy components from the vehicle (engine
and transmission assembly, rear axle, gearbox), use a
four-post lift.

If the vehicle is on a two-post lift, there is a danger that
it will tip after removal of these types of components.
Fit the safety strap(s) available from Spare Parts De-
partment.

120616

02A-2

LIFTING EQUIPMENT

2 - Fitting the straps

Vehicle: Towing and lifting

3 - Permitted jacking points

Front lifting points

02A

120612

For safety reasons, these straps must always be in
perfect condition. Replace them as soon as they show

signs of wear.
When fitting the straps, check that the seats and fragile

parts of the vehicle are correctly protected.

If there is a danger of the vehicle tipping forward:

- place the strap under the rear right-hand arm of the
lift,

- pass the strap through the inside of the vehicle,

- pass the strap under the left-hand rear arm of the lift,

- pass the strap through the inside of the vehicle again,

- tighten the strap.

If there is a danger of the vehicle tipping bac­kwards:

- place the strap under the front right-hand arm of the
lift,

- pass the strap through the inside of the vehicle,

-pass the strap under the front left-hand arm of the lift,

- pass the strap through the inside of the vehicle again,

120613

Rear lifting points

120615

- tighten the strap.

IMPORTANT

Only the jacking points described in this section
allow the vehicle to be raised in complete safety.

Do not raise the vehicle using points other than
those described in this section.

02A-3

LIFTING EQUIPMENT

Vehicle: Towing and lifting

To raise the vehicle, position the lifting arm pads as
shown above, taking care not to damage the end of the
front wing and the underside of the sill panel.

02A

02A-4

COLLISION

Vehicle involved in an impact: Impact fault finding

SUB-FRAME INSPECTION

03B

a

1 - Chronological order of checks:

a FRONT impact

-1: (B) - (Ad) = (Bd) - (A)

-2: (B) - (Gd) = (Bd) - (G)

a REAR impact

-1: (A) - (Bd) = (Ad) - (B)

-2: (G) - (Bd) = (Gd) - (B)

121744

03B-1

COLLISION

Vehicle involved in an impact: Impact fault finding

2 - Detailed view of inspection points

Point A, Ad: Front subframe rear mounting

Points G, Gd: Front side member rear mounting

Points C, Cd: Front side member front mounting

03B

121750

Points B, Bd: Rear axle leader pin

121747

121752

121746

03B-2

COLLISION

Vehicle involved in an impact: Impact fault finding

Points J, Jd: Rear side member rear leader pin

03B

121748

121749

a

03B-3

COLLISION

Vehicle involved in a frontal impact: Description

COMBINATIONS FOR REPLACING WELDED
STRUCTURAL PARTS IN ACCORDANCE WITH
IMPACT SUSTAINED

03B

121903

03B-4

COLLISION

Vehicle involved in a frontal impact: Description

1st degree

03B

- (1) front end cross member

- (2) front side member closure panel

- (3) front side member front section

- (4) front wheel arch, front section

121904

03B-5

COLLISION

Vehicle involved in a frontal impact: Description

2nd Degree

03B

- (5) front right-hand wheel arch

- (6) front left-hand wheel arch

- (7) front side member front section

- (8) front side member closure panel

- (9) front side cross member

- (10) scuttle side panel

- (11) scuttle side panel upper reinforcement

121905

3rd Degree

121906

- (12) right-hand half unit

- (13) front side member rear section

- (14) left-hand half unit

03B-6

COLLISION

Vehicle involved in a side impact: Description

03B

1st Degree

121899

- (4) sill panel

121900

- (1) A-pillar

- (2) upper body

- (3) scuttle side panel upper reinforcement

03B-7

COLLISION

Vehicle involved in a side impact: Description

2nd Degree

03B

- (5) scuttle side panel

- (6) windscreen pillar lining

- (7) side roof rail lining

- (8) A-pillar reinforcement

- (9) scuttle side panel upper reinforcement

- (10) sill panel reinforcement

- (11) sill panel stiffener

- (12) B-pillar reinforcement

121901

03B-8

COLLISION

Vehicle involved in a side impact: Description

3rd Degree

03B

- (13) roof

- (14) windscreen aperture lower cross member clo-
sure panel

- (15) roof front section

- (16) roof front cross member

- (17) roof centre cross member

- (18) roof rear cross member

- (19) roof rear section

- (20) front cross member under front seat

- (21) rear cross member under front seat

- (22) rear floor

- (23) inner sill panel

- (24) centre floor

121902

03B-9

COLLISION

Vehicle involved in a rear impact: Description

03B

1st Degree

121895

121896

- (1) rear wing panel

- (2) rear light mounting

- (3) rear end panel

03B-10

COLLISION

Vehicle involved in a rear impact: Description

2nd Degree

03B

- (4) rear side member

- (5) rear floor

- (6) tow eye mounting

- (7) rear end panel lining

- (8) quarter panel lining

121897

03B-11

COLLISION

Vehicle involved in a rear impact: Description

3rd Degree

03B

- (9) rear floor centre cross member

- (10) rear side member assembly

- (11) inner wheel arch

- (12) quarter panel upper rear reinforcement

- (13) quarter panel lining

121898

03B-12

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

Consumables for mechanical repair:

DEFINITION PACKAGING PART NUMBER

MECHANICAL SEALANTS

SILICOR

sealing paste

MASTIXO

Joint face seal

BEARING SEALING KIT

For crankshaft bearing cap side
sealing

SILICONE ADHESIVE SEAL

Engine and gearbox sealing paste

TRANSPARENT SEALING MAS­TIC

85 g tube 77 11 236 470

100 g tube 77 11 236 172

Kit 77 11 237 896

100 g cartridge 77 11 227 484

45 g tube 77 11 223 369

04B

SILICOJOINT 90 g tube 77 11 236 469
LOCTITE ADHESIVE 597

Sealing paste for PXX gearboxes

RESIN ADHESIVE or SEALING
RESIN

Sealing resin for engine and gear­box covers

EXHAUST MASTIC

For exhaust pipe union seals

LEAK DETECTOR 400 ml aerosol 77 11 236 176

FRENETANCHE

Sealing the threading at low and
medium pressure

HIGH-STRENGTH THREADLOCK

For locking bolts

Cartridge 77 11 219 705

25 ml tube 77 11 237 640

1.5 kg tin 77 01 421 161

ADHESIVES

50 ml bottle 77 11 236 471

50 ml bottle 77 11 230 112

SEALING RESIN

For locking the bearings

NÉTELEC

Avoid bad contacts in electrical cir­cuits

50 ml bottle 77 11 236 472

LUBRICANT CLEANERS

150 ml aerosol 77 11 225 871

04B-1

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

INJECTOR CLEANER 355 ml container 77 11 224 188 or 77 11 225 539
CLOTH FOR INJECTION SYSTEM 77 11 211 707
SUPER RELEASING AGENT 500 ml aerosol 77 11 236 166
SUPER RELEASING AGENT 250 ml aerosol 77 11 420 439
SUPER CLEANER FOR JOINT

FACES

For cleaning joint faces

SURFACE CLEANER 5 L container 77 01 404 178
SILICONE LUBRICANT 500 ml aerosol 77 11 236 168
SILICONE-FREE LUBRICANT 500 ml aerosol 77 11 236 167

BRAKE CLEANER

300 ml aerosol 77 11 238 181

600 ml aerosol 77 11 422 413
150 ml aerosol 77 11 422 414

04B

BIO BRAKE CLEANER 750 ml spray bottle 77 11 427 217
AIR CONDITIONING CLEANER 250 ml aerosol 77 11 230 498
CARBURETTOR CLEANER Aerosol 77 11 236 177
IXTAR ENGINE CLEANER 400 ml can 77 11 229 365

GREASE

BR2+ GREASE

For:

- the lower arm bearings,

- the anti-roll bar grooves,

- the driveshaft splines.

SILICONE GREASE

For:

- the tubular rear axle bushes,

- the anti-roll bar bushes.

COPPER ANTI-SEIZE GREASE

1 kg pack 77 01 421 145

100 g tube 77 11 419 216

85 g tube 77 11 236 173

Grease for turbochargers (high
temperature)

COPPER-ALUMINIUM LUBRI­CANT

Grease for turbochargers (high
temperature)

GREASE

For driveshaft seals

500 ml aerosol 77 11 236 169

180 g sachets 77 11 420 011

04B-2

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

WHITE GREASE

For wheel sensors

MULTIPURPOSE GREASE

FLUORSTAR 2L

Silicone-free electric sealing grease

JELT ARGENT

Varnish for repairing heated rear
screens

DOT 4, ISO CLASS 6, RENAULT
STANDARD: 03-50-006,

For vehicles with and without elec­tronic stability program (ESP)

04B

400 ml aerosol 77 11 236 174

500 ml aerosol 77 11 236 170
250 ml aerosol 77 11 236 171
100 g tube 82 00 168 855

LACQUER

5 g bottle 77 11 230 111

BRAKE

0.5 L container 77 11 218 589
5 L container 77 11 238 318
25 L container 77 11 238 319

DOT 4, ISO CLASS 4, RENAULT
STANDARD: 03-50-005

Authorised for vehicles without ESP

DOT 4

Authorised for vehicles without
ESP, without clutch with hydraulic
tappet

ANTIFREEZE (TYPE D) 1 L container 77 11 170 548

COOLANT (TYPE D)

ENGINE OIL (see Engine oil: Specifications) (Technical Note 6013A, 04A, Lubri-

0.5 L container 77 11 172 381
5 L container 77 01 395 503
25 L container 77 11 171 926

0.5 L container 86 71 000 000
5 L container 86 71 014 277
25 L container 86 71 014 278

COOLING SYSTEM

1 L container 77 11 171 589
2 L container 77 11 170 545
5 L container 77 11 170 546

OIL

cants)

GEARBOX OIL

(see Manual gearbox oil: Specifications) (Technical Note 6012A, 04A,

Lubricants)

(see Automatic gearbox oil: Specifications) (Technical Note 6012A,

04A, Lubricants)

(see Sequential gearbox oil: Specifications) (Technical Note 6012A,

04A, Lubricants)

04B-3

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

AXLE OIL (see Rear axle oil: Specifications) (Technical Note 6012A, 04A, Lubri-

cants)

ELF RENAULT MATIC D2

Oil for power-assisted steering:
Pump connected, pump assembly
(except Laguna III)

TOT AL POWER-ASSISTED
STEERING FLUID

Oil for power-assisted steering:
Pump assembly (Laguna III)

PLANETELF PAG 488
SANDEN SP 10

Oil for air conditioning compressor

2 L container 77 01 402 037

1 L container

77 11 172 668

250 ml container

TYRES

77 01 419 313

04B

1 kg pack 77 11 223 052

TYRE PASTE

5 kg pack 77 11 223 053
400 ml tube 77 11 221 296

TYRE REPAIR AGENT

300 ml tube 77 11 222 802

BLANKING PLUG

Engine type Injection type Part no.

F5R 77 01 206 382
F8Q 77 01 206 340
F9Q 77 01 208 229
G9T AND G9U 77 01 208 229
K9K DELPHI 77 01 206 804
K9K SIEMENS 77 01 476 857
M9R 77 01 209 062
P9X 77 01 474 730
ZD3 77 01 208 229

MISCELLANEOUS

GREY ABRASIVE PAD 77 01 405 943

Consumables for bodywork repair:

HOLLOW SECTION WAX

SPR CC 1 L container 77 11 172 672

04B-4

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

SPR CC SPRAY 500 ml aerosol 77 11 211 654

STRUCTURAL ADHESIVE

STRUCTURAL ADHESIVE Kit =2 80 ml cartridges 77 11 219 885
HIGH PERFORMANCE STRUC-

TURAL ADHESIVE

MONOPAC EVOLUTION ADHE­SIVE KIT

MONOPAC EVOLUTION ADDI­TIONAL CARTRIDGE + NOZZLE

S-P KIT ADHESIVE KIT 310 ml cartridge 77 11 421 432
ADDITIONAL S-P KIT CAR-

TRIDGE + NOZZLE

1 195 ml cartridge 77 11 419 113

GLAZING PRODUCTS AND ADHESIVES

310 ml cartridge 77 11 421 430

310 ml cartridge 77 11 421 431

310 ml cartridge 77 11 421 433

04B

BIPAC EVOLUTION ADHESIVE
KIT

LINT-FREE CLOTH Box of 340 cloths 77 11 237 262
WINDOW SEALING MASTIC 310 ml cartridge 77 11 170 222
SPECIAL ADHESIVE FOR WIN-

DOWS
ADHESION PROMOTER

For bonding double-sided adhesive
tape

DOUBLE-SIDED ADHESIVE 18 mm wide 77 11 226 308
DOUBLE-SIDED ADHESIVE 8 mm wide 77 11 427 869
FRENETANCHE 50 ml bottle 77 11 236 471
ADHESIVE PATCH 82 00 043 181
ADHESIVE PAD 77 05 042 163

2 225 ml cartridges 77 11 421 434

77 11 425 759

Cloth 77 11 423 222

MISCELLANEOUS

SEALS

BLACK MJ PRO (Electroweldable) 310 ml cartridge 77 11 172 676
WHITE MJ PRO II (Electroweld-

able)

PREFORMED SEALING MASTIC
BEAD

BRUSH MASTIC 1 kg pack 77 11 228 113
FILLER MASTIC 60 beads Ø 6 mm by 0.3 m 77 11 170 230

310 ml cartridge 77 11 426 951

2.6 m roll 77 01 423 330

04B-5

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

GREASE

WHITE GREASE 400 ml aerosol 77 11 236 174
OPENING ELEMENT MECHA-

NISM GREASE
SILICONE LUBRICANT 500 ml aerosol 77 11 236 168
SILICONE-FREE LUBRICANT 500 ml aerosol 77 11 236 167

SPR GREY EVOLUTION 1 l cartridge 77 11 419 114
SPR GREY EVOLUTION SPRAY 400 ml aerosol 77 11 419 116
SPR BLACK EVOLUTION II 1 l cartridge 77 11 419 115
SOUNDPROOFING PAD (3.5 Kg/

m²)

20 g sachets 77 11 419 865

SOUNDPROOFING

Pack of 10 77 01 423 546

04B

SOUNDPROOFING PAD (6.5 Kg/

m²)

POLISHING LIQUID 1 L container 77 11 420 288
FINISHING LIQUID 1 L container 77 11 420 289

GALAXI 2.5 kg pack 77 11 172 238
OPTIMAX 1.23 l cartridge 77 11 172 239

EXCELLENCE +

For finishing plastic repair

XFIBRE FIBREGLASS MASTIC 975 kg pack 77 11 172 235
STANDARD BASIX POLYESTER

MASTIC

Pack of 5 77 01 423 269

POLISHING

MASTIC

Universal mastic

960 g cartridge 77 11 423 539
1 kg pack 77 11 423 540

Plugging mastic

1.975 kg pack 77 11 172 234

ALUX ALUMINIUM MASTIC 975 kg pack 77 11 172 236

Sprayable mastic

PIXTO SPRAYABLE POLYESTER
MASTIC

IXTRA POLYESTER MASTIC 1.625 kg pack 77 11 172 233

1.5 kg tin 77 11 172 237

Finishing mastic

Anti-grit mastic

04B-6

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

MAG PRO 1 310 ml cartridge 77 11 172 679
MAG PRO 3 (Dual component) 1.5 kg tin 77 11 218 364

SURFACE CLEANER

HEPTANE 500 ml container 77 11 170 064
SOLVENT SURFACE CLEANER 5 L container 77 01 404 178
WATER-BASED SURFACE

CLEANER
ANTISTATIC THINNER (for plastic

materials)

PLASTIC REPAIR KIT 77 11 170 064
NOZZLE FOR PLASTIC REPAIR

KIT

5 L container 77 11 421 337

400 ml aerosol 77 01 408 493

COMPOSITE MATERIAL REPAIR BY BONDING

77 11 423 523

04B

PLASTIC REPAIR CLEANER 1 L container 77 11 423 517
PLASTIC REPAIR PRIMER 150 ml bottle 77 11 423 518
PLASTIC REPAIR ADHESIVE 2 x 25 ml bicomponent cartridge 77 11 423 519
PLASTIC REPAIR CLOTH 90 m roller 77 11 423 520
PLASTIC REPAIR NOZZLES 12 nozzles 77 11 423 522

COMPOSITE MATERIAL REPAIR BY WELDING

PLASTIC WELD REPAIR SET 77 11 425 742
PROTECTIVE STRIPS Bag of 10 protective strips 77 11 425 744
STAINLESS STEEL MESH Bag of 2 meshes 77 11 425 743
COOLER 400 ml aerosol 77 11 425 745
BRUSH Box of 10 brushes 77 11 237 793

WINDOW MASKING TAPE

10 MM WINDSCREEN TAPE 77 11 171 708
20 MM WINDSCREEN TAPE 77 11 171 709

PROTECTIVE WELDING

ANTI-SPLASH SPRAY 400 ml aerosol 77 11 218 270

SPECIFIED UNDERCOAT

PRE-TREATMENT PRIMER WITH­OUT ZINC CHROMATE (I-Alpha) +

THINNER

1 L container

77 11 420 027 (Primer)
77 11 420 028 (Thinner)

04B-7

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

I-PREMIA REACTIVE PRIMER (do

not use on aluminium)

I-PREMIA REACTIVE PRIMER (do
not use on aluminium)

ADHÉRA SPRAY (adhesion pro­moter for thermoplastics)

PRIMARA BLACK (adhesion pro­moter/primer for thermoplastics)

PRIMARA (adhesion promoter/
primer for thermoplastics)

LEVIA 3.5 l container 77 11 228 651

3.5 l container

400 ml aerosol 77 11 419 416

400 ml aerosol 77 11 423 734

1 L container

1 L container

UNDERCOAT

77 11 239 243 (Primer)
77 11 228 654 (Thinner)

77 11 423 735
77 11 171 514 (Activator)
77 11 171 513
77 11 171 514 (Activator)

04B

FORTIA 3.5 l container 77 11 228 650

04B-8

PAINT

Anti-corrosion protection product: Description

I - POINTS LOCATED INSIDE THE VEHICLE

04E

Note:
Hollow body parts to be treated from inside the

vehicle must be treated after painting and before
retrimming.

Side impact:

- replacing or repairing the sill panel:

• protection of the join between the inner sill panel and

the sill panel reinforcement: injection of wax into
points (1) and (2) ,

•protection of the join between the sill panel and the

sill panel closure: injection of wax into points (4) and
(5) .

- replacing the quarter panel lining:

• injection of wax into points (16) and (17) .

121909

- replacing the centre side member beneath the floor:

• injection of wax into points (6) , (8) and (7) .

04E-1

PAINT

Anti-corrosion protection product: Description

II - POINTS BENEATH THE VEHICLE

04E

Note:
Blanking pieces are fitted to the injection points

located beneath the vehicle. When any work is car­ried out on the vehicle, plug all the points used for
injection. Replace any damaged or deformed blank­ing pieces with new ones.

Frontal impact:

- replacing or repairing the front side member, the front
side member closure panel and the front sub-frame
mounting unit:

• injection of wax into points (3) and (9) .

- replacing the front side cross member or the front half
unit:

• injection of wax into points (10) and (11) .

Rear impact:

- replacing the complete rear side member:

• injection of wax into points (12) and (13) .

121910

- replacing the rear floor centre cross member:

•injection of wax into points (13) and (14) .

III - PRODUCTS AND EQUIPMENT FOR TREATING
HOLLOW SECTIONS

The products and equipment required for carrying out
this work are available from the Parts Department.

- Replacement of the rear end panel:

• injection of wax into point (15) .

04E-2

PAINT

Anti-corrosion protection product: Description

« PAC1, PAC2 » kit

04E

Protective wax

272-2

The hollow body parts of the structure of the vehicle
are protected in the factory by injecting hot wax. To

guarantee equivalent protection after repair, inject one
after the other the two complementary products which
make up a « PAC1, PAC2 » kit.

After injection, all the orifices must be covered using
blanking covers moulded to fit each one.

The necessary information concerning blanking covers
can be found in the Parts Catalogue for the vehicle.

Injector assembly

272

The subframe under the floor is protected with a spe­cial wax.

IV - OPERATING PROCEDURE FOR TREATING
HOLLOW SECTIONS

(18) Wax flow control
(19) Quick-release union end piece
(20) Interchangeable injection hose

272-1

109692

Insert the nozzle tip until it reaches the end of the hol­low section (21) .

Inject the wax whilst retracting the nozzle tip (22) .

04E-3

0

General vehicle information

01A

01C

01D

02A

03B

04B

04E

VEHICLE MECHANICAL SPECIFICATIONS

VEHICLE BODYWORK SPECIFICATIONS

MECHANICAL INTRODUCTION

LIFTING EQUIPMENT

COLLISION

CONSUMABLES - PRODUCTS

PAINT

NOVEMBER 2009 EDITION ANGLAISE

"The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are

constructed".

X44

© Renault s.a.s 2007

All rights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part reference

numbering system is forbidden without the prior written authority of Renault.

TWINGO - Section 0 ContentsPages

TWINGO - Section 0

Contents

Pages

01A VEHICLE MECHANICAL SPECIFICATIONS

Vehicle: Specifications 01A-1

01C VEHICLE BODYWORK SPECIFICATIONS

Vehicle: Identification 01C-1
Vehicle panel gaps:

Adjustment value 01C-3

01D MECHANICAL INTRODUCTION

Vehicle: Precautions for the
repair 01D-1

Tightening torques: General
information 01D-3

03B COLLISION

Vehicle involved in a side
impact: Description 03B-7

Vehicle involved in a rear
impact: Description 03B-10

04B CONSUMABLES - PRODUCTS

Vehicle: Parts and
consumables for the repair 04B-1

04E PAINT

Anti-corrosion protection
product: Description 04E-1

02A LIFTING EQUIPMENT

Vehicle: Towing and lifting 02A-1

03B COLLISION

Vehicle involved in an
impact: Impact fault finding 03B-1

Vehicle involved in a frontal
impact: Description 03B-4

VEHICLE MECHANICAL SPECIFICATIONS

Vehicle: Specifications

01A

Dimensions in metres

A 0.710 / 0.714 (RS)
B 2.367
C 0.525
D 3.602
E 1.400 / 1.414 (GT, RS)
F 1.470 (unladen)
G 1.386 / 1.400 (GT) / 1.430 (RS)
H 1.655

122555

01A-1

VEHICLE MECHANICAL SPECIFICATIONS

Vehicle: Specifications

Engine type Engine suf-fixCubic

capacity(cc)

772

D4F

1149

780
782 309 EURO 5

D7F 800 JB1 520

Gearbox Gearbox

suffix

521
523

JB1

JH1

JH3

524
525 EURO 5
020 EURO 4
021 EURO 5
169 EURO 4

01A

Emissions
standard

EURO 4

K4M 854 1598 JR5 176

K9K

718

1461

740 JH3 166

JR5 193

EURO 4

01A-2

VEHICLE BODYWORK SPECIFICATIONS

Vehicle: Identification

I - LOCATION OF VEHICLE IDENTIFICATION
PLATE

01C

III - DETAILED VIEW OF THE VEHICLE
IDENTIFICATION PLATE

Plate (A)

120451

II - LOCATION OF THE VEHICLE IDENTIFICATION
NUMBER

120452

19031

(1) Vehicle type and type number;

this information also appears on
marking (B)

(2) MPAW (Vehicle's Maximum Per-

missible All-up Weight)

(3) GTW (Gross train weight, vehi-

cle under load with trailer)

(4) Maximum permissible front axle

load

(5) Maximum permissible rear axle

load
(6) Technical vehicle specifications
(7) Paintwork reference number
(8) Equipment level
(9) Vehicle type
(10) Upholstery code
(11) Additional equipment details
(12) Production number
(13) Interior trim code

01C-1

VEHICLE BODYWORK SPECIFICATIONS

Vehicle: Identification

IV - COLD-MARKING OF THE BODY

Marking (B)

01C

121197

Note:
If the complete body is being replaced, it must be

marked in compliance with the current regulations.

01C-2

VEHICLE BODYWORK SPECIFICATIONS

Vehicle panel gaps: Adjustment value

01C

WARNING

The clearance values are given for information pur­poses.

When adjusting clearances, certain rules have to be
followed:

- maintain symmetry with respect to the opposite
side,

- ensure the flush fitting is correct,

- check correct operation of the opening, and water/
air-tightness.

All values are given in millimetres.

Section 1

120453

120385

(X1) = 3.5 ±±±± 1.5

01C-3

VEHICLE BODYWORK SPECIFICATIONS

Section 2

Vehicle panel gaps: Adjustment value

Section 4

01C

(X2) = 2 ±±±± 1.5

Section 3

120382

120383

(X4) = 3.5 ±±±± 1.5

Section 5

(X3) = 3 ±±±± 1.5

120381

120384

(X5) = 2 ±±±± 1.3

01C-4

VEHICLE BODYWORK SPECIFICATIONS

Section 6

Vehicle panel gaps: Adjustment value

Section 8

01C

(X6) = 2 ±±±± 1.3

Section 7

120386

120388

(X8) = 2.5 ±±±± 1.3

Section 9

(X7) = 0 + 1/- 0

120380

120392

= 4.2 ±±±± 1

01C-5

VEHICLE BODYWORK SPECIFICATIONS

Section 10

Vehicle panel gaps: Adjustment value

Section 12

01C

(X10) = 2 ±±±± 1.5

Section 11

120387

120393

(X12) = 4 ±±±± 1.5

Section 13

(X11) = 5 ±±±± 2

120390

120394

(X13) = 4 ±±±± 2.3

01C-6

VEHICLE BODYWORK SPECIFICATIONS

Vehicle panel gaps: Adjustment value

Section 14 (X14) = 5.5 ±±±± 1.5

01C

120389

01C-7

120454

VEHICLE BODYWORK SPECIFICATIONS

Section 15

Vehicle panel gaps: Adjustment value

Section 17

01C

(X15) = 5.3 ±±±± 1

Section 16

120395

120397

(X17) = 1.5 ±±±± 1

Section 18

(X16) = 4.5 ±±±± 1.5

120396

120398

(X18) = 4 ±±±± 1.8

01C-8

VEHICLE BODYWORK SPECIFICATIONS

Section 19

Vehicle panel gaps: Adjustment value

Section 21

01C

(X19) = 1.5 ±±±± 1.5

Section 20

120400

120399

(X21) = 6 ±±±± 1.8

Section 22

(X20) = 0 + 1/- 0

120401

120391

(X22) = 2.5 ±±±± 1

01C-9

MECHANICAL INTRODUCTION

Vehicle: Precautions for the repair

GENERAL INFORMATION

All information contained in these manuals is intended
exclusively for automotive industry professionals.

The documentation is intended to cover all vehicles in
the RENAULT range throughout the world, but may not
cover equipment designed for use in specific countries.

The procedures and fault finding procedures recom­mended and described in this manual have been de­signed by automotive industry repair professionals.

1 - General recommendations

Observe basic principles of vehicle repair.
The quality of repair depends first and foremost on the

care exercised by the person in carrying it out.
To ensure good repair:

- protect the sensitive areas of the vehicle (seats,
steering wheel, wings, etc.),

-unless otherwise indicated, all repairs must be done
with the ignition off,

01D

- protect the accessories and timing belts, the electrical
accessories (starter, blanking cover, electric power

assisted steering pump) and the mating face to pre­vent diesel fuel spilling onto the clutch friction plate.

The design quality of our vehicles demands that noth­ing is left to chance in making a good repair, and it is

essential to refit parts or components exactly as they
were originally (for instance: heat shields, wiring rout­ing, pipe routing, particularly in the area of the exhaust
pipe).

Do not blow away asbestos particles or dust (brakes,
clutch, etc.), vacuum them up or clean the component

with a cleaning agent (such as a brake cleaning prod­uct).

Use professional products and apply them with care,
for example do not apply too much sealing paste to the

sealing surface.
Exhaust gases (petrol and diesel) are pollutants. Oper-

ate engines with care and always use exhaust gas ex­tractors.

- when welding on the vehicle, it is advisable to remove
or disconnect components near the repair area that

could be affected by the heat,

- use recommended professional products and original
parts,

- observe the tightening torques,

- replace roll pins, self-locking or bonded nuts or bolts
every time they are removed,

- take care with electrical and electronic components
which cannot withstand excess voltage and improper
handling; replace any electrical and electronic com­ponents which have experienced a voltage drop,

- make sure that the connectors are correctly clipped,

- do not pull on the wiring,

- check for the sealing plugs on the connectors,

- Do not splash any liquid, regardless of its type (oil,
cleaner, etc.), on the electric and electronic compo­nents (computers, sensors, etc.)

- do not just replace parts one after the other, carry out
detailed fault finding beforehand,

-carry out a final check before returning the vehicle to
the customer (set the clock, check the alarm opera­tion, check the lights and indicators etc.),

- clean and degrease the sections to be bonded
(threads, stub axle splines) to ensure proper adher­ence,

Ensure that there is no risk of a short circuit occurring
when the electrical connections are reconnected (e.g.

starter, alternator, etc.). Some points need greasing,
others do not, therefore particular attention should be
paid during refitting operations to ensure that they work
properly under all conditions.

2 - Special tooling - ease of use

The repair procedures have been designed using spe­cial tools; they must therefore be carried out using

these tools to ensure a high degree of working safety
and quality of repair.

The equipment we have approved has undergone
careful research and testing, and must be used and

maintained with care.

3 - Reliability - updating

New repair procedures are constantly being developed
in the interests of repair quality, either with new prod-

ucts (emission control, injection, electronics, etc.), or in
fault finding. Be sure to consult the Workshop Repair

Manuals or Technical Notes or fault finding summaries
before any servicing operation.

Since vehicle specifications are subject to change dur­ing their commercial life, it is essential to check wheth­er there are any updated Technical Notes when
seeking information.

01D-1

MECHANICAL INTRODUCTION

Vehicle: Precautions for the repair

4 - Safety

Operations on certain equipment and certain parts (for
instance: spring-shock absorber assembly, automatic
transmission, brake system, ABS, airbag, common rail
diesel injection, LPG, etc.) require particular attention
to be paid to safety, cleanliness and care.

The safety symbol used in this manual indicates that
special attention must be paid to the procedure or the
tightening torque values.

Working safely:

- use suitable tools which are in good condition (use of
« multi-purpose » tools, such as adjustable pliers,
etc., should be avoided wherever possible),

- use supports and adopt a correct posture when per­forming heavy work or raising loads,

- make sure that the procedure used is not dangerous,

01D

5 - Conclusion

The procedures contained in this document merit your
attention. Please read them carefully in order to reduce
the risk of injury, and avoid using incorrect procedures
that could damage the vehicle or make it dangerous in
use.

Following the recommended procedures will help you
to provide a quality of service which will ensure the ve­hicles achieve the highest levels of performance and
reliability.

Maintenance and repair operations must be carried out
under the proper conditions to ensure that our vehicles
run safely and reliably.

- Do not wear any jewellery or other small objects dur­ing an operation,

- use personal protection (gloves, safety glasses, work
shoes, masks, skin barrier creams, etc.),

- always follow the safety instructions associated with
the operation to be performed,

- do not smoke when working on vehicles,

- use smoke extractors (welding, exhaust gases, etc.),

- do not use harmful products in unventilated rooms,

- do not overstrain yourself or attempt inappropriate
work operations,

- use axle stands when working under a vehicle raised
on a jack,

- do not ingest any chemicals (brake fluid, coolant,
etc.),

- do not open the cooling circuit when it is hot and pres­surised,

- take care with components that are liable to start up
suddenly (engine cooling fan, etc.).

Respecting the environment:

-do not allow waste refrigerants to escape into the at­mosphere,

- do not dispose of waste vehicle fluids (oil, brake fluid,
etc.) in drains,

- do not burn discarded products (tyres, etc.).

01D-2

MECHANICAL INTRODUCTION

Tightening torques: General information

I - TABLE OF STANDARD TORQUES

Fastenings Standard

tightening

Diameter Property

class

M6 8.8 10
M8 8.8 25
M10 8.8 50

M10 10.9 62
M12 10.9 105

M14 10.9 180
M16 10.9 280

torque
(N.m)

01D

The property class is indicated on the bolt (1) or (2) .

II - FUNCTION OF A BOLTED ASSEMBLY

The bolting system connects parts of an assembly to
prevent their separation or sliding when submitted to
exterior forces.

Exterior forces

M18 10.9 400

Special notes on electrical earths

Fastenings Standard

tightening

Diameter

M6 8
M8 21
M10 44

torque
(N.m)

120737

The assembly is submitted to forces that are:

- static and / or dynamic,

- simple (e.g. simple traction),

- multiple (traction + flexion + torsion).

120736

01D-3

MECHANICAL INTRODUCTION

Tightening torques: General information

Creating tension (or preload) F0

01D

Customer complaints resulting from incorrect tighten­ing may be, following assembly, a safety issue (fire,
loss of control of the vehicle etc.), an immobilising fault
or a noise.

III - TIGHTENING PROCEDURES

The two controlled tightening procedures adapted to
automotive repairs because of their low cost and sim­ple operation are torque tightening and angle tighten­ing (also called torque and angle).

1 - Torque tightening

This is the most commonly used procedure. Is consists
of tightening until a given resisting torque is reached,
known as tightening torque.

The tightening torque is distributed in a large part as
friction torque (under the head and in the thread) and in
a small part as useful torque (to create the tension).

120738

The assembly is held together by the tension created in
the bolt when it is tightened.

A reliable assembly is only possible if the correct ten­sion is used:

- insufficient tension: risk of loosening,

- too much tension: risk of deformation of the parts to
be assembled, or shearing of the bolt.

This practise spreads the tension significantly due to
the variation in the friction coefficients from one assem­bly to another and the uncertainty of the tightening pro­cedures and methods.

2 - Angle tightening

The principle consists of putting the parts of the assem­bly in contact using a mating torque (approximately 25
to 30% of the final torque) then to tighten to a deter­mined angle.

This method, which is not dependent on the friction of
the tightened assembly, gives more precise results
than torque tightening.

IV - OBSERVING THE TIGHTENING TORQUES AND
ANGLES

Bolted assemblies whose tightening torques and an­gles are explicitly specified in the removal / refitting
procedures must be observed using the appropriate
tools (torque wrench, angle measuring disc). Failure to
observe this can lead to safety risks, immobilising
faults or unwanted noises.

(3) Bolt
(4) Assembled components
(5) Extension of the bolt
(6) Non-tightened assembly
(7) Tightened assembly

(X1) compression of the assembly
(Fo) tension
(C) tightening torque

120739

For other bolted assemblies, non-measured tightening
(using standard spanners) is acceptable. Neverthe­less, the corresponding tightening torque is indicated in
the table of standard tightening torques.

V - RECOMMENDED TIGHTENING TOOLS

For measured tightening, the repairer must have avail­able torque wrenches to tighten from 4 to 400 N.m as
well as an angle measuring disc.

The torque wrenches used may be click type or elec­tronic.

01D-4

MECHANICAL INTRODUCTION

Tightening torques: General information

For example:

-1 torque wrench 4 - 40 N.m,

-1 torque wrench 20 - 100 N.m,

-1 torque wrench 80 - 400 N.m,

-1 angle measurement disc.

The torque wrenches used must comply with the ISO
6789 standard. They must be calibrated regularly fol­lowing the supplier's recommendations using the ap­propriate procedures.

VI - PRECAUTIONS WHEN USING A CLICK TYPE
TORQUE WRENCH

A click type torque wrench is a manual tightening tool.
The trigger mechanism causes a break or disengage­ment of the wrench past a force threshold.

This threshold depends on the setting of the wrench
but also depends on the way the wrench is handled.

01D

120741

- Pull the wrench gently and steadily, without applying
any torsion. Excessive tightening speed as well as jerk­iness are major causes of overtightening. Any torsion
applied to the wrench will alter the trigger threshold.

- Hold the wrench on the bolt using a minimum of effort.
Any effort applied to the wrench head will alter the trig-

ger threshold.

When used following best practises, the accuracy of
the tightness when using a click type torque wrench is

± 15%.
The instructions to be observed are:

120742

- Apply the tightening effort perpendicular to the mount­ing observing a tolerance of ± 15˚ relative to the per-
pendicularity. If the wrench is not perpendicular to the
mounting axis, this will result in insufficient tightening.

120740

(6) lever arm

- Place the hand in the centre of the handle. An incor-

rectly positioned hand on the handle will alter the trig­ger threshold.

- Stop tightening as soon as the wrench is triggered.
Continued tightening after the wrench is triggered will
lead to overtightening.

01D-5

MECHANICAL INTRODUCTION

Tightening torques: General information

It is advisable to handle the wrench with care and to
stop tightening when the required value is displayed on
the wrench.

01D

120743

If the length of the wrench is modified (extending the
handle, adapting an end piece) it is essential to recali­brate the wrench to its new configuration.

Modifying the length of the wrench will modify its trigger
threshold.

Use the formula: C1 = CO x L2 / (L1+L2)

- CO: torque to apply,

- C1: adjustment torque to be displayed on the wrench,

- L1: length of the extension,

- L2: length of the wrench.

Unless there are special instructions in the repair meth­od, a universal joint (CARDAN joint type) should be
used for measured tightening. Using a universal joint
will result in a difference between the set torque of the
wrench and the actual torque applied.

Before storing the wrench, loosen the adjustment
spring completely. A wrench stored with a spring under
tension will lose its tightening accuracy.

VII - PRECAUTIONS WHEN USING ELECTRONIC
TORQUE WRENCHES

An electronic torque wrench is a manual tightening
tool. The tightening torque and, depending on the mod­el, the angle is read directly.

When used following best practises, the accuracy of
the tightness when using an electronic torque wrench
is ± 5%.

Electronic torque wrenches are not affected by the po­sition of the operator's hand.

01D-6

LIFTING EQUIPMENT

Vehicle: Towing and lifting

Equipment required

Diagnostic tool
safety strap(s)

I - TOWING

WARNING

See the current towing regulations in each country.
Never use the drive shafts as attachment points.
The towing points may only be used for towing on

the road.
Never use the towing points for removing the vehi-

cle from a ditch or to lift the vehicle, either directly
or indirectly.

02A

1 - Position of front attachment point

Screw in and lock the towing ring before towing.
Vehicles fitted with automatic transmission:

- The vehicle should preferably be transpor ted on a

platform or towed b y lifting the front wheels. As an
exception, the vehicle may be towed with the
wheels on the ground but at a speed below 12

mph (20km/h) and over a maximum distance of
18 miles (30 kms) (with the gear lever in neutral).

Vehicles fitted with Renault Card:

- If the vehicle battery is flat, the steering column

remains locked. In this case, fit a new battery or
connect to an electrical source to lock the airbag
computer using the Diagnostic tool (see Airbag
and pretensioners: Precautions for the repair)
(88C, Airbag and pretensioners), which unlocks
the steering column.

-If it is not possible to lock the airbag computer, the

front of the vehicle must be lifted.

120735

2 - Position of rear attachment point

II - LIFTING BY TROLLEY JACK

IMPORTANT

To prevent any accidents, the trolley jack must only
be used to lift and/or move the vehicle. The vehicle

height must be maintained with axle stands which
are strong enough to support the weight of the vehi­cle.

02A-1

120450

LIFTING EQUIPMENT

Vehicle: Towing and lifting

WARNING

To avoid any damage to the original protection, use
equipment fitted with rubber pads to prevent the
equipment coming into direct contact with the vehi­cle.

To avoid any damage to the axle assemblies, the
vehicle must not be raised using the front suspen­sion arms for support or under the rear axle.

02A

To mount the vehicle onto axle stands, lift the entire ve­hicle on one side and the axle stands must be placed
under zones (1) and (2) designed for positioning the
tool kit jack.

III - LIFTING ON A LIFT

1 - Safety advice reminder

120614

14894

To remove heavy components from the vehicle (engine
and transmission assembly, rear axle, gearbox), use a
four-post lift.

If the vehicle is on a two-post lift, there is a danger that
it will tip after removal of these types of components.
Fit the safety strap(s) available from Spare Parts De-
partment.

120616

02A-2

LIFTING EQUIPMENT

2 - Fitting the straps

Vehicle: Towing and lifting

3 - Permitted jacking points

Front lifting points

02A

120612

For safety reasons, these straps must always be in
perfect condition. Replace them as soon as they show

signs of wear.
When fitting the straps, check that the seats and fragile

parts of the vehicle are correctly protected.

If there is a danger of the vehicle tipping forward:

- place the strap under the rear right-hand arm of the
lift,

- pass the strap through the inside of the vehicle,

- pass the strap under the left-hand rear arm of the lift,

- pass the strap through the inside of the vehicle again,

- tighten the strap.

If there is a danger of the vehicle tipping bac­kwards:

- place the strap under the front right-hand arm of the
lift,

- pass the strap through the inside of the vehicle,

-pass the strap under the front left-hand arm of the lift,

- pass the strap through the inside of the vehicle again,

120613

Rear lifting points

120615

- tighten the strap.

IMPORTANT

Only the jacking points described in this section
allow the vehicle to be raised in complete safety.

Do not raise the vehicle using points other than
those described in this section.

02A-3

LIFTING EQUIPMENT

Vehicle: Towing and lifting

To raise the vehicle, position the lifting arm pads as
shown above, taking care not to damage the end of the
front wing and the underside of the sill panel.

02A

02A-4

COLLISION

Vehicle involved in an impact: Impact fault finding

SUB-FRAME INSPECTION

03B

a

1 - Chronological order of checks:

a FRONT impact

-1: (B) - (Ad) = (Bd) - (A)

-2: (B) - (Gd) = (Bd) - (G)

a REAR impact

-1: (A) - (Bd) = (Ad) - (B)

-2: (G) - (Bd) = (Gd) - (B)

121744

03B-1

COLLISION

Vehicle involved in an impact: Impact fault finding

2 - Detailed view of inspection points

Point A, Ad: Front subframe rear mounting

Points G, Gd: Front side member rear mounting

Points C, Cd: Front side member front mounting

03B

121750

Points B, Bd: Rear axle leader pin

121747

121752

121746

03B-2

COLLISION

Vehicle involved in an impact: Impact fault finding

Points J, Jd: Rear side member rear leader pin

03B

121748

121749

a

03B-3

COLLISION

Vehicle involved in a frontal impact: Description

COMBINATIONS FOR REPLACING WELDED
STRUCTURAL PARTS IN ACCORDANCE WITH
IMPACT SUSTAINED

03B

121903

03B-4

COLLISION

Vehicle involved in a frontal impact: Description

1st degree

03B

- (1) front end cross member

- (2) front side member closure panel

- (3) front side member front section

- (4) front wheel arch, front section

121904

03B-5

COLLISION

Vehicle involved in a frontal impact: Description

2nd Degree

03B

- (5) front right-hand wheel arch

- (6) front left-hand wheel arch

- (7) front side member front section

- (8) front side member closure panel

- (9) front side cross member

- (10) scuttle side panel

- (11) scuttle side panel upper reinforcement

121905

3rd Degree

121906

- (12) right-hand half unit

- (13) front side member rear section

- (14) left-hand half unit

03B-6

COLLISION

Vehicle involved in a side impact: Description

03B

1st Degree

121899

- (4) sill panel

121900

- (1) A-pillar

- (2) upper body

- (3) scuttle side panel upper reinforcement

03B-7

COLLISION

Vehicle involved in a side impact: Description

2nd Degree

03B

- (5) scuttle side panel

- (6) windscreen pillar lining

- (7) side roof rail lining

- (8) A-pillar reinforcement

- (9) scuttle side panel upper reinforcement

- (10) sill panel reinforcement

- (11) sill panel stiffener

- (12) B-pillar reinforcement

121901

03B-8

COLLISION

Vehicle involved in a side impact: Description

3rd Degree

03B

- (13) roof

- (14) windscreen aperture lower cross member clo-
sure panel

- (15) roof front section

- (16) roof front cross member

- (17) roof centre cross member

- (18) roof rear cross member

- (19) roof rear section

- (20) front cross member under front seat

- (21) rear cross member under front seat

- (22) rear floor

- (23) inner sill panel

- (24) centre floor

121902

03B-9

COLLISION

Vehicle involved in a rear impact: Description

03B

1st Degree

121895

121896

- (1) rear wing panel

- (2) rear light mounting

- (3) rear end panel

03B-10

COLLISION

Vehicle involved in a rear impact: Description

2nd Degree

03B

- (4) rear side member

- (5) rear floor

- (6) tow eye mounting

- (7) rear end panel lining

- (8) quarter panel lining

121897

03B-11

COLLISION

Vehicle involved in a rear impact: Description

3rd Degree

03B

- (9) rear floor centre cross member

- (10) rear side member assembly

- (11) inner wheel arch

- (12) quarter panel upper rear reinforcement

- (13) quarter panel lining

121898

03B-12

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

Consumables for mechanical repair:

DEFINITION PACKAGING PART NUMBER

MECHANICAL SEALANTS

SILICOR

sealing paste

MASTIXO

Joint face seal

BEARING SEALING KIT

For crankshaft bearing cap side
sealing

SILICONE ADHESIVE SEAL

Engine and gearbox sealing paste

TRANSPARENT SEALING MAS­TIC

85 g tube 77 11 236 470

100 g tube 77 11 236 172

Kit 77 11 237 896

100 g cartridge 77 11 227 484

45 g tube 77 11 223 369

04B

SILICOJOINT 90 g tube 77 11 236 469
LOCTITE ADHESIVE 597

Sealing paste for PXX gearboxes

RESIN ADHESIVE or SEALING
RESIN

Sealing resin for engine and gear­box covers

EXHAUST MASTIC

For exhaust pipe union seals

LEAK DETECTOR 400 ml aerosol 77 11 236 176

FRENETANCHE

Sealing the threading at low and
medium pressure

HIGH-STRENGTH THREADLOCK

For locking bolts

Cartridge 77 11 219 705

25 ml tube 77 11 237 640

1.5 kg tin 77 01 421 161

ADHESIVES

50 ml bottle 77 11 236 471

50 ml bottle 77 11 230 112

SEALING RESIN

For locking the bearings

NÉTELEC

Avoid bad contacts in electrical cir­cuits

50 ml bottle 77 11 236 472

LUBRICANT CLEANERS

150 ml aerosol 77 11 225 871

04B-1

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

INJECTOR CLEANER 355 ml container 77 11 224 188 or 77 11 225 539
CLOTH FOR INJECTION SYSTEM 77 11 211 707
SUPER RELEASING AGENT 500 ml aerosol 77 11 236 166
SUPER RELEASING AGENT 250 ml aerosol 77 11 420 439
SUPER CLEANER FOR JOINT

FACES

For cleaning joint faces

SURFACE CLEANER 5 L container 77 01 404 178
SILICONE LUBRICANT 500 ml aerosol 77 11 236 168
SILICONE-FREE LUBRICANT 500 ml aerosol 77 11 236 167

BRAKE CLEANER

300 ml aerosol 77 11 238 181

600 ml aerosol 77 11 422 413
150 ml aerosol 77 11 422 414

04B

BIO BRAKE CLEANER 750 ml spray bottle 77 11 427 217
AIR CONDITIONING CLEANER 250 ml aerosol 77 11 230 498
CARBURETTOR CLEANER Aerosol 77 11 236 177
IXTAR ENGINE CLEANER 400 ml can 77 11 229 365

GREASE

BR2+ GREASE

For:

- the lower arm bearings,

- the anti-roll bar grooves,

- the driveshaft splines.

SILICONE GREASE

For:

- the tubular rear axle bushes,

- the anti-roll bar bushes.

COPPER ANTI-SEIZE GREASE

1 kg pack 77 01 421 145

100 g tube 77 11 419 216

85 g tube 77 11 236 173

Grease for turbochargers (high
temperature)

COPPER-ALUMINIUM LUBRI­CANT

Grease for turbochargers (high
temperature)

GREASE

For driveshaft seals

500 ml aerosol 77 11 236 169

180 g sachets 77 11 420 011

04B-2

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

WHITE GREASE

For wheel sensors

MULTIPURPOSE GREASE

FLUORSTAR 2L

Silicone-free electric sealing grease

JELT ARGENT

Varnish for repairing heated rear
screens

DOT 4, ISO CLASS 6, RENAULT
STANDARD: 03-50-006,

For vehicles with and without elec­tronic stability program (ESP)

04B

400 ml aerosol 77 11 236 174

500 ml aerosol 77 11 236 170
250 ml aerosol 77 11 236 171
100 g tube 82 00 168 855

LACQUER

5 g bottle 77 11 230 111

BRAKE

0.5 L container 77 11 218 589
5 L container 77 11 238 318
25 L container 77 11 238 319

DOT 4, ISO CLASS 4, RENAULT
STANDARD: 03-50-005

Authorised for vehicles without ESP

DOT 4

Authorised for vehicles without
ESP, without clutch with hydraulic
tappet

ANTIFREEZE (TYPE D) 1 L container 77 11 170 548

COOLANT (TYPE D)

ENGINE OIL (see Engine oil: Specifications) (Technical Note 6013A, 04A, Lubri-

0.5 L container 77 11 172 381
5 L container 77 01 395 503
25 L container 77 11 171 926

0.5 L container 86 71 000 000
5 L container 86 71 014 277
25 L container 86 71 014 278

COOLING SYSTEM

1 L container 77 11 171 589
2 L container 77 11 170 545
5 L container 77 11 170 546

OIL

cants)

GEARBOX OIL

(see Manual gearbox oil: Specifications) (Technical Note 6012A, 04A,

Lubricants)

(see Automatic gearbox oil: Specifications) (Technical Note 6012A,

04A, Lubricants)

(see Sequential gearbox oil: Specifications) (Technical Note 6012A,

04A, Lubricants)

04B-3

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

AXLE OIL (see Rear axle oil: Specifications) (Technical Note 6012A, 04A, Lubri-

cants)

ELF RENAULT MATIC D2

Oil for power-assisted steering:
Pump connected, pump assembly
(except Laguna III)

TOT AL POWER-ASSISTED
STEERING FLUID

Oil for power-assisted steering:
Pump assembly (Laguna III)

PLANETELF PAG 488
SANDEN SP 10

Oil for air conditioning compressor

2 L container 77 01 402 037

1 L container

77 11 172 668

250 ml container

TYRES

77 01 419 313

04B

1 kg pack 77 11 223 052

TYRE PASTE

5 kg pack 77 11 223 053
400 ml tube 77 11 221 296

TYRE REPAIR AGENT

300 ml tube 77 11 222 802

BLANKING PLUG

Engine type Injection type Part no.

F5R 77 01 206 382
F8Q 77 01 206 340
F9Q 77 01 208 229
G9T AND G9U 77 01 208 229
K9K DELPHI 77 01 206 804
K9K SIEMENS 77 01 476 857
M9R 77 01 209 062
P9X 77 01 474 730
ZD3 77 01 208 229

MISCELLANEOUS

GREY ABRASIVE PAD 77 01 405 943

Consumables for bodywork repair:

HOLLOW SECTION WAX

SPR CC 1 L container 77 11 172 672

04B-4

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

SPR CC SPRAY 500 ml aerosol 77 11 211 654

STRUCTURAL ADHESIVE

STRUCTURAL ADHESIVE Kit =2 80 ml cartridges 77 11 219 885
HIGH PERFORMANCE STRUC-

TURAL ADHESIVE

MONOPAC EVOLUTION ADHE­SIVE KIT

MONOPAC EVOLUTION ADDI­TIONAL CARTRIDGE + NOZZLE

S-P KIT ADHESIVE KIT 310 ml cartridge 77 11 421 432
ADDITIONAL S-P KIT CAR-

TRIDGE + NOZZLE

1 195 ml cartridge 77 11 419 113

GLAZING PRODUCTS AND ADHESIVES

310 ml cartridge 77 11 421 430

310 ml cartridge 77 11 421 431

310 ml cartridge 77 11 421 433

04B

BIPAC EVOLUTION ADHESIVE
KIT

LINT-FREE CLOTH Box of 340 cloths 77 11 237 262
WINDOW SEALING MASTIC 310 ml cartridge 77 11 170 222
SPECIAL ADHESIVE FOR WIN-

DOWS
ADHESION PROMOTER

For bonding double-sided adhesive
tape

DOUBLE-SIDED ADHESIVE 18 mm wide 77 11 226 308
DOUBLE-SIDED ADHESIVE 8 mm wide 77 11 427 869
FRENETANCHE 50 ml bottle 77 11 236 471
ADHESIVE PATCH 82 00 043 181
ADHESIVE PAD 77 05 042 163

2 225 ml cartridges 77 11 421 434

77 11 425 759

Cloth 77 11 423 222

MISCELLANEOUS

SEALS

BLACK MJ PRO (Electroweldable) 310 ml cartridge 77 11 172 676
WHITE MJ PRO II (Electroweld-

able)

PREFORMED SEALING MASTIC
BEAD

BRUSH MASTIC 1 kg pack 77 11 228 113
FILLER MASTIC 60 beads Ø 6 mm by 0.3 m 77 11 170 230

310 ml cartridge 77 11 426 951

2.6 m roll 77 01 423 330

04B-5

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

GREASE

WHITE GREASE 400 ml aerosol 77 11 236 174
OPENING ELEMENT MECHA-

NISM GREASE
SILICONE LUBRICANT 500 ml aerosol 77 11 236 168
SILICONE-FREE LUBRICANT 500 ml aerosol 77 11 236 167

SPR GREY EVOLUTION 1 l cartridge 77 11 419 114
SPR GREY EVOLUTION SPRAY 400 ml aerosol 77 11 419 116
SPR BLACK EVOLUTION II 1 l cartridge 77 11 419 115
SOUNDPROOFING PAD (3.5 Kg/

m²)

20 g sachets 77 11 419 865

SOUNDPROOFING

Pack of 10 77 01 423 546

04B

SOUNDPROOFING PAD (6.5 Kg/

m²)

POLISHING LIQUID 1 L container 77 11 420 288
FINISHING LIQUID 1 L container 77 11 420 289

GALAXI 2.5 kg pack 77 11 172 238
OPTIMAX 1.23 l cartridge 77 11 172 239

EXCELLENCE +

For finishing plastic repair

XFIBRE FIBREGLASS MASTIC 975 kg pack 77 11 172 235
STANDARD BASIX POLYESTER

MASTIC

Pack of 5 77 01 423 269

POLISHING

MASTIC

Universal mastic

960 g cartridge 77 11 423 539
1 kg pack 77 11 423 540

Plugging mastic

1.975 kg pack 77 11 172 234

ALUX ALUMINIUM MASTIC 975 kg pack 77 11 172 236

Sprayable mastic

PIXTO SPRAYABLE POLYESTER
MASTIC

IXTRA POLYESTER MASTIC 1.625 kg pack 77 11 172 233

1.5 kg tin 77 11 172 237

Finishing mastic

Anti-grit mastic

04B-6

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

MAG PRO 1 310 ml cartridge 77 11 172 679
MAG PRO 3 (Dual component) 1.5 kg tin 77 11 218 364

SURFACE CLEANER

HEPTANE 500 ml container 77 11 170 064
SOLVENT SURFACE CLEANER 5 L container 77 01 404 178
WATER-BASED SURFACE

CLEANER
ANTISTATIC THINNER (for plastic

materials)

PLASTIC REPAIR KIT 77 11 170 064
NOZZLE FOR PLASTIC REPAIR

KIT

5 L container 77 11 421 337

400 ml aerosol 77 01 408 493

COMPOSITE MATERIAL REPAIR BY BONDING

77 11 423 523

04B

PLASTIC REPAIR CLEANER 1 L container 77 11 423 517
PLASTIC REPAIR PRIMER 150 ml bottle 77 11 423 518
PLASTIC REPAIR ADHESIVE 2 x 25 ml bicomponent cartridge 77 11 423 519
PLASTIC REPAIR CLOTH 90 m roller 77 11 423 520
PLASTIC REPAIR NOZZLES 12 nozzles 77 11 423 522

COMPOSITE MATERIAL REPAIR BY WELDING

PLASTIC WELD REPAIR SET 77 11 425 742
PROTECTIVE STRIPS Bag of 10 protective strips 77 11 425 744
STAINLESS STEEL MESH Bag of 2 meshes 77 11 425 743
COOLER 400 ml aerosol 77 11 425 745
BRUSH Box of 10 brushes 77 11 237 793

WINDOW MASKING TAPE

10 MM WINDSCREEN TAPE 77 11 171 708
20 MM WINDSCREEN TAPE 77 11 171 709

PROTECTIVE WELDING

ANTI-SPLASH SPRAY 400 ml aerosol 77 11 218 270

SPECIFIED UNDERCOAT

PRE-TREATMENT PRIMER WITH­OUT ZINC CHROMATE (I-Alpha) +

THINNER

1 L container

77 11 420 027 (Primer)
77 11 420 028 (Thinner)

04B-7

CONSUMABLES - PRODUCTS

Vehicle: Parts and consumables for the repair

I-PREMIA REACTIVE PRIMER (do

not use on aluminium)

I-PREMIA REACTIVE PRIMER (do
not use on aluminium)

ADHÉRA SPRAY (adhesion pro­moter for thermoplastics)

PRIMARA BLACK (adhesion pro­moter/primer for thermoplastics)

PRIMARA (adhesion promoter/
primer for thermoplastics)

LEVIA 3.5 l container 77 11 228 651

3.5 l container

400 ml aerosol 77 11 419 416

400 ml aerosol 77 11 423 734

1 L container

1 L container

UNDERCOAT

77 11 239 243 (Primer)
77 11 228 654 (Thinner)

77 11 423 735
77 11 171 514 (Activator)
77 11 171 513
77 11 171 514 (Activator)

04B

FORTIA 3.5 l container 77 11 228 650

04B-8

PAINT

Anti-corrosion protection product: Description

I - POINTS LOCATED INSIDE THE VEHICLE

04E

Note:
Hollow body parts to be treated from inside the

vehicle must be treated after painting and before
retrimming.

Side impact:

- replacing or repairing the sill panel:

• protection of the join between the inner sill panel and

the sill panel reinforcement: injection of wax into
points (1) and (2) ,

•protection of the join between the sill panel and the

sill panel closure: injection of wax into points (4) and
(5) .

- replacing the quarter panel lining:

• injection of wax into points (16) and (17) .

121909

- replacing the centre side member beneath the floor:

• injection of wax into points (6) , (8) and (7) .

04E-1

PAINT

Anti-corrosion protection product: Description

II - POINTS BENEATH THE VEHICLE

04E

Note:
Blanking pieces are fitted to the injection points

located beneath the vehicle. When any work is car­ried out on the vehicle, plug all the points used for
injection. Replace any damaged or deformed blank­ing pieces with new ones.

Frontal impact:

- replacing or repairing the front side member, the front
side member closure panel and the front sub-frame
mounting unit:

• injection of wax into points (3) and (9) .

- replacing the front side cross member or the front half
unit:

• injection of wax into points (10) and (11) .

Rear impact:

- replacing the complete rear side member:

• injection of wax into points (12) and (13) .

121910

- replacing the rear floor centre cross member:

•injection of wax into points (13) and (14) .

III - PRODUCTS AND EQUIPMENT FOR TREATING
HOLLOW SECTIONS

The products and equipment required for carrying out
this work are available from the Parts Department.

- Replacement of the rear end panel:

• injection of wax into point (15) .

04E-2

PAINT

Anti-corrosion protection product: Description

« PAC1, PAC2 » kit

04E

Protective wax

272-2

The hollow body parts of the structure of the vehicle
are protected in the factory by injecting hot wax. To

guarantee equivalent protection after repair, inject one
after the other the two complementary products which
make up a « PAC1, PAC2 » kit.

After injection, all the orifices must be covered using
blanking covers moulded to fit each one.

The necessary information concerning blanking covers
can be found in the Parts Catalogue for the vehicle.

Injector assembly

272

The subframe under the floor is protected with a spe­cial wax.

IV - OPERATING PROCEDURE FOR TREATING
HOLLOW SECTIONS

(18) Wax flow control
(19) Quick-release union end piece
(20) Interchangeable injection hose

272-1

109692

Insert the nozzle tip until it reaches the end of the hol­low section (21) .

Inject the wax whilst retracting the nozzle tip (22) .

04E-3

1

Engine and peripherals

10A

11A

12A

12B

13A

13B

13C

ENGINE AND CYLINDER BLOCK ASSEMBLY

TOP AND FRONT OF ENGINE

FUEL MIXTURE

TURBOCHARGING

FUEL SUPPLY

DIESEL INJECTION

PREHEATING

14A

16A

17A

17B

"The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are

constructed".

ANTIPOLLUTION

STARTING - CHARGING

IGNITION

PETROL INJECTION

NOVEMBER 2009 EDITION ANGLAISE

X44

All rights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part reference

numbering system is forbidden without the prior written authority of Renault.

© Renault s.a.s 2007

19A

COOLING

19B

19C

19D

EXHAUST

TANK

ENGINE MOUNTING

NOVEMBER 2009 EDITION ANGLAISE

"The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are

constructed".

X44

© Renault s.a.s 2007

All rights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part reference

numbering system is forbidden without the prior written authority of Renault.

TWINGO - Chapitre 1ContentsPages

TWINGO - Chapitre 1

Contents

Pages

10A

ENGINE AND CYLINDER BLOCK
ASSEMBLY

Crankshaft seal on timing
end: Removal - Refitting 10A-1

Crankshaft seal, gearbox
end: Removal - Refitting 10A-3

Lower cover: Removal ­Refitting 10A-6

Engine oil: Draining ­Refilling 10A-22

Oil filter: Removal - Refitting 10A-29
Oil-coolant heat exchanger:

Removal - Refitting 10A-33
Conrod bearing shell:

Removal - Refitting 10A-37
Oil pressure sensor:

Removal - Refitting 10A-45
Oil pump: Removal -

Refitting 10A-50
Oil pressure: Check 10A-59
Multifunction support:

Removal - Refitting 10A-63

11A TOP AND FRONT OF ENGINE

Pressure at end of
compression: Check 11A-1

Accessories belt: Removal ­Refitting 11A-3

Crankshaft accessories
pulley: Removal - Refitting 11A-20

Timing belt: Removal ­Refitting 11A-27

Rocker cover: Removal ­Refitting 11A-66

Camshaft: Removal ­Refitting 11A-82

Cylinder head: Removal ­Refitting 11A-114

Camshaft dephaser:
Removal - Refitting 11A-135

Camshaft seal, timing end:
Removal - Refitting 11A-138

Oil decanter: Removal ­Refitting 11A-147

Engine - gearbox assembly:
Removal - Refitting 10A-74

Valves: Adjustment 10A-105
Flywheel: Removal - Refitting 10A-107

12A FUEL MIXTURE

Air inlet: Description 12A-1
Air filter: Removal - Refitting 12A-6
Air filter unit: Removal -

Refitting 12A-13

Contents

12A FUEL MIXTURE

Air resonator: Removal ­Refitting 12A-19

Throttle valve: Removal ­Refitting 12A-20

Throttle valve: Cleaning 12A-26
Air flowmeter: Removal -

Refitting 12A-28
Inlet distributor: Removal -

Refitting 12A-29
Injector holder shim:

Removal - Refitting 12A-45
Exhaust manifold: Removal -

Refitting 12A-48

12B TURBOCHARGING

Turbocharging: Precautions
for the repair 12B-1

Turbocharger: Removal ­Refitting 12B-4

Turbocharger oil pipe:
Removal - Refitting 12B-12

Intercooler: Removal ­Refitting 12B-18

13A FUEL SUPPLY

Fuel pressure: Check 13A-9
Fuel flow: Check 13A-14

13B DIESEL INJECTION

Diesel injection: Precautions
for the repair 13B-1

Diesel injection: List and
location of components 13B-8

Diesel injection computer:
Removal - Refitting 13B-13

Camshaft position sensor:
Removal - Refitting 13B-14

Crankshaft position sensor:
Removal - Refitting 13B-15

High pressure pump:
Removal - Refitting 13B-16

Flow actuator: Removal ­Refitting 13B-26

Venturi: Removal - Refitting 13B-31
High pressure pipe: Check 13B-34
High pressure pipe between

pump and rail: Removal ­Refitting 13B-35

13A FUEL SUPPLY

Diesel supply circuit:
Operating diagram 13A-1

Manual priming pump:
Removal - Refitting 13A-2

Fuel filter: Removal ­Refitting 13A-4

Electric diesel fuel heater:
Removal - Refitting 13A-7

Fuel circuit: Operating
diagram 13A-8

High pressure pipe between
rail and injector: Removal ­Refitting 13B-39

Injector rail: Removal ­Refitting 13B-43

Rail pressure sensor:
Removal - Refitting 13B-48

Fuel temperature sensor:
Removal - Refitting 13B-49

Injector leak flow: Check 13B-51
Accelerometer: Removal -

Refitting 13B-53

Contents

13C PREHEATING

Pre-postheating unit:
Removal - Refitting 13C-1

Heater plugs: Removal ­Refitting 13C-2

14A ANTIPOLLUTION

Oil vapour rebreathing
circuit: Descriptions 14A-1

Fuel vapour recirculation
circuit: Operating diagram 14A-2

Fuel vapour recirculation
circuit: Check 14A-3

Fuel vapour absorber:
Removal - Refitting 14A-4

Fuel vapour absorber: Check 14A-7
Fuel vapour absorber bleed

solenoid valve: Removal ­Refitting 14A-8

17A IGNITION

Coils: Removal - Refitting 17A-1
Plugs: Removal - Refitting 17A-12

17B PETROL INJECTION

Petrol injection: List and
location of components 17B-1

Oxygen sensors: Removal ­Refitting 17B-13

Petrol injection computer:
Removal - Refitting 17B-20

Pinking sensor: Removal ­Refitting 17B-23

Crankshaft position sensor:
Removal - Refitting 17B-25

Injector rail - Injectors:
Removal - Refitting 17B-27

Exhaust gas recirculation
solenoid valve: Removal ­Refitting 14A-10

Exhaust gas cooler: Removal

- Refitting 14A-11
Exhaust gas recirculation

assembly: Removal ­Refitting 14A-15

Exhaust gas recirculation
rigid pipe: Removal ­Refitting 14A-19

16A STARTING - CHARGING

Alternator: Removal ­Refitting 16A-1

Starter: Removal - Refitting 16A-10
Alternator pulley: Removal -

Refitting 16A-17

19A COOLING

Engine cooling system:
Specifications 19A-1

Engine cooling system:
Check 19A-2

Engine cooling circuit: List
and location of components 19A-4

Engine cooling system:
Operating diagram 19A-5

Cooling system: Draining ­Refilling 19A-9

Cooling radiator: Removal ­Refitting 19A-12

Coolant pump: Removal ­Refitting 19A-24

Thermostat: Removal ­Refitting 19A-34

Water chamber: Removal ­Refitting 19A-40

Contents

19A COOLING

Engine cooling fan assembly:
Removal - Refitting 19A-51

Coolant pump inlet pipe:
Removal - Refitting 19A-58

Expansion bottle: Removal ­Refitting 19A-64

Coolant temperature sensor:
Removal - Refitting 19A-66

19B EXHAUST

Exhaust: List and location of
components 19B-1

Exhaust: Precautions for the
repair 19B-8

Catalytic converter: Removal

- Refitting 19B-12

19D ENGINE MOUNTING

Suspended engine
mounting: Tightening torque 19D-1

Left-hand suspended engine
mounting: Removal ­Refitting 19D-4

Right-hand suspended
engine mounting: Removal ­Refitting 19D-13

Lower engine tie-bar:
Removal - Refitting 19D-18

Expansion chamber:
Removal - Refitting 19B-23

Intermediate pipe: Removal ­Refitting 19B-28

Silencer: Removal - Refitting 19B-31

19C TANK

Fuel tank: Draining 19C-1
Fuel tank: Removal -

Refitting 19C-4
Filler neck: Removal -

Refitting 19C-11
Fuel level sensor module:

Removal - Refitting 19C-13

ENGINE AND CYLINDER BLOCK ASSEMBLY

Crankshaft seal on timing end: Removal - Refitting

K4M

Special tooling required

Mot. 1385 Tool for fitting the crankshaft

seal, timing end (35 x 47 x 7).

REMOVAL

I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).

a Disconnect the battery (see Battery: Removal - Re-

fitting) (80A, Battery).

a Remove:

-the engine undertray,

-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),

- the right-hand suspended engine mounting (see

19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,

- the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,

- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,

- the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-

ting, page 11A-135) .

II - REMOVAL OPERATION

10A

-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-

terior protection),

-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),

-the headlights (see Halogen headlight: Removal

- Refitting) (80B, Headlights),

-the bonnet catch (see Bonnet lock: Removal -
Refitting) (52A, Non-side opening element mecha­nisms),

-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper

front structure),

-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,

page 11A-3) ,

-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,

-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-20) ,

130542

a Remove the crankshaft timing end seal (1) .

REFITTING

I - REFITTING PREPARATION OPERATION
a parts always to be replaced: Crankshaft seal on

timing end.

-the windscreen wiper arms (see Windscreen wip­er arm: Removal - Refitting) (85A, Wiping -

Washing),

-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 - Refit­ting) (56A, Exterior equipment),

10A-1

ENGINE AND CYLINDER BLOCK ASSEMBLY

Crankshaft seal on timing end: Removal - Refitting

K4M

a Use SURFACE CLEANER (see Vehicle: Parts

and consumables for the repair) (04B, Consuma-

bles - Products) to clean and degrease:

-the mating face of the crankshaft seal at the timing
end,

-the crankshaft seal housing at the timing end of the
cylinder block.

WARNING

The joint faces must be clean, dr y and free from
grease (avoid finger marks).

II - REFITTING OPERATION

- the scoop under the scuttle panel grille (see Scoop

under the scuttle panel grille: Removal - Refit­ting) (56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),

- the windscreen wiper arms (see Windscreen wip­er arm: Removal - Refitting) (85A, Wiping -

Washing),

-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-20) ,

- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,

- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,

-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper
front structure),

10A

14523

a Refit a new crankshaft seal at the timing end, using

the tool (Mot. 1385) (2) .

III - FINAL OPERATION

a Refit:

-the camshaft dephaser (see 11A, Top and front of

engine, Camshaft dephaser: Removal - Refit­ting, page 11A-135) ,

- the bonnet catch (see Bonnet lock: Removal ­Refitting) (52A, Non-side opening element mecha-

nisms),

- the headlights (see Halogen headlight: Removal

- Refitting) (80B, Headlights),

- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),

- the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex­terior protection),

-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),

- the engine undertray.

a Connect the battery (see Battery: Removal - Refit-

ting) (80A, Battery).

-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,

-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,

-the right-hand suspended engine mounting (see

19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,

10A-2