2009 RENAULT TWINGO Chasiss Workshop Manual

30A-13
GENERAL INFORMATION
Rigid brake pipe: Repair
30A
This procedure applies to copper pipes diameter 4.7
mm.
REPAIR
I - PIPE PREPARATION OPERATION
a
aCut the pipe to the recommended length using a
tube cutter (see Garage equipment catalogue).
aPut the nuts or bolts on the pipe before forming the
rivets.
II - MAKING THE RIVETS
a Equipment required
compressed air nozzle
Tightening torquesm
brake pipe bolts8 N.m
underbody unions
(female/male)6 N.m
Note:
This procedure does not apply to:
-hybrid pipes (pipe + hose),
-pipes with diameters 6 mm and 8 mm.
WARNING
To avoid causing a breakdown in hydraulic brake
circuit , do not squash or bend the rigid pipe
when cutting.
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Note:
To make the r ivets, fit the rivet press in a vice.

30A-14
GENERAL INFORMATION
Rigid brake pipe: Repair
30A
aFit the pipe in the rivet press (see Garage Equip-
ment Catalogue).
aAdjust the length of the pipe to be shaped.
aTorque tighten the press end piece(40 N.m).
III - CHECKING THE RIVETS
aVisually inspect:
-the uniformity of the rivets' diameter,
-the rivet centring in relation to the pipe shaft.aVisually check that the internal diameter of the pipe
is not oval-shaped.
aCheck that the diameter of the end panel is not oval
shaped using a sliding calliper.
Correct diameter if (X1) = (X2)
IV - PREPARATION OF THE PIPE BEFORE
BENDING
a
aBlow inside the pipe in both directions using a com-
pressed air nozzle.
aPut plugs on the bolts or nuts at the ends of the pipe.
aPut the original pipe on a flat base plate that is the
length of the pipe.
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Note:
Impurities may spread inside the pipe while the
rivets are being made.

30A-15
GENERAL INFORMATION
Rigid brake pipe: Repair
30A
aMeasure the dimensions (X3) (in mm) curve after
curve, between each curve radius « centre » (1) of
the old pipe.
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30A-16
GENERAL INFORMATION
Rigid brake pipe: Repair
30A
a
aShape the pipe using a bender, curve after curve,
while respecting the original shape of the pipe.
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WARNING
To avoid weakening the pipe, either bend once or
bend progressively by increasing the bend (that
is, by continually decreasing the curve radius).
Do not install a rigid pipe on a vehicle that may
have been bended and then unbended alterna-
tively to reach the correct curve radius.
Note:
During the bending operation, the required angle
should be passed slightly in order to compensate
for material elasticity.

30A-17
GENERAL INFORMATION
Rigid brake pipe: Repair
30A
V - CHECKING BENDING
aCheck the out-of-roundness of the outer diameter at
the centre of the curve radius (2) using a sliding cal-
liper (the out-of-roundness of the outer diameter is
correct if it is less than 10% flattening):
-nominal diameter of the pipe: 4.75 mm,
-minimum diameter after bending: 4.30 mm.VI - REFITTING THE PIPE
a
aTorque tighten the brake pipe bolts (8 N.m).
aTorque tighten the underbody unions (female/
male) (6 N.m).
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Note:
When refitting the rigid brake pipe:
-respect the original routing as much as possi-
ble,
-adjust the pipe routing by hand when fitting
inside the clips.
WARNING
Contact points between the rigid brake pipe and
the surrounding components could cause dam-
age to the pipe. In order to avoid these contacts,
adjust the pipe routing by hand.
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30A-18
GENERAL INFORMATION
Brake fluid: Specifications
30A
BRAKE FLUID REPLACEMENT INTERVAL
Our braking technology, and in particular the disc
brakes (hollow pistons which conduct little heat, have a
low volume of fluid in the cylinder, sliding callipers
avoiding the need for a fluid reserve in the least cooled
area of the wheel), has allowed us to prevent the risk of
« vapour lock » as far as possible, even with heavy
braking (mountainous area). However, current brake
fluids are subject to minor deterioration during the first
months of use due to slight humidity intake. This is why
it is recommended that you change the brake fluid: see
maintenance booklet for the vehicle.
1 - Topping up the level
Wear of the brake pads will result in a gradual drop in
the fluid level in the reservoir.
Do not top up the fluid, as the level will rise again when
the pads are next changed. The brake fluid level must
not fall below the minimum mark.
2 - Approved brake fluid
Mixing two incompatible brake fluids in the brake circuit
may lead to:
-serious risk of leakage due mainly to deterioration of
the cups,
-deterioration in the operation of the ESP system.
To prevent such risks, it is essential to use only brake
fluids that comply with the RENAULT standard (see
Vehicle: Parts and consumables for the repair) .

30A-19
GENERAL INFORMATION
Brake: Specifications
30A
(1) the brake discs cannot be repaired. The brake discs
must be replaced if they are excessively scratched or
worn.Full front brake discs Ventilated front brake discs
Front brake (mm)
Piston diameter 48 48 57
Disc diameter 259 259 280
Disc thickness 12 20.6 24
Minimum disc thickness
(1)10.6 17.7 21.8
Maximum disc run-out 0.03
Brake pad thickness
(including backplate)18 17.5
Minimum pad thickness
(including backplate)68.2
Rear drum brake (mm)
Slave cylinder diameter 17.5
Drum diameter 203.2
Maximum diameter of
drum wear204.45
Drum pad thickness
(including suppor t)5.5
Minimu m d ru m lining
thickness (including
mounting)2.4
Rear disc brake (mm)
Piston diameter 34
Disc diameter 240
Disc thickness 8
Minimum disc thickness
(1)7
Maximum disc run-out 0.06
Brake pad thickness
(including backplate)16
Minimum pad thickness
(including backplate)6

30A-20
GENERAL INFORMATION
Steering: Tightening torque
30A
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