2009 RENAULT TWINGO Panelwork Workshop Manual

40A-4
GENERAL INFORMATION
Specialised bodywork tools: Use
40A
aComponents of tool Car. 1504 :
- (1) : Mandrel mounting,
- (2) : Mandrels,
- (3) : Tightening bolt,
- (4) : Body,
- (5) : Anvils,
- (6) : Special nut,
- (7) : Nut,
- (8) : Studs,
- (9) : Thrust nut.
1 - Tool preparation
aSelect the mandrel, anvil and insert assembly adap-
ted to the crimping operation to be carried out.
aScrew the mandrel (2) into the mandrel mounting (1)
(left-hand thread).
aTighten the bolt (3) onto the body (4) until the stop
(left-hand thread).
aScrew the anvil (5) into the body (4) (left-hand
thread)
aFit the assembly (1) and (2) into the body of the tool.
aScrew the insert (left-hand thread) onto the pull rod.2 - Using the tool
aTurn the tightening bolt (3) using a 24 mm wrench
while holding the tool handle.
Note:
To fi t the special nut (6) , insert the mandrel (2)
through the nut to be crimped and tighten it onto
the thrust nut (9) .
WARNING
Each time a panel is stripped in the workshop
(e.g. when drilling), degrease and wipe the area
and then use a fine paintbrush to apply the fol-
lowing:
-a pre-treatment primer,
-a two-part pr imer,
-paint in the vehicle body colour.
WARNING
The operator should be able to feel when the
crimping is complete (more force required for
tightening).
The insert has been crimped correctly when
there is no rotational play. Carry out this check
before unscrewing the « pull rod - mandrel »
assembly.

40A-5
GENERAL INFORMATION
Vehicle on repair bench: Description
C44
40A
I - MAIN FRONT TRIM-SETTING REFERENCE
POINTS
1 - Front sub-frame in place
the jig covers the subframe bolt (A) .
Use this situation for a rear impact or a light frontal im-
pact without removing the mechanical components.
2 - Front sub-frame removed
The jig rests against the rear section of the side mem-
ber and is centred in the sub-frame rear mounting hole
(A) .Use this situation for a frontal impact with removal of
the mechanical components.
II - SECONDARY FRONT TRIM-SETTING
REFERENCE POINT
The jig covers the front subframe front mounting bolt
(C) .
Use this situation to confirm the trim-setting following a
rear impact, (e.g.: to replace a rear side member as-
sembly).
It is used to confirm the vehicle level in case of doubt
about the deformation of a main rear reference point.
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Note:
If it is suspected that one of these points may be
deformed, use two additional points located in an
area not affected by the impact in order to confirm
trim-setting.
120610

40A-6
GENERAL INFORMATION
Vehicle on repair bench: Description
C44
40A
III - TRIM-SETTING MAIN REAR REFERENCE
POINTS
1 - Rear mechanical components in place
The jig supports the underside of the rear axle fork and
is centred in the rear axle bolt tapped hole (B) .
Use this situation for a frontal impact or a light rear im-
pact.
2 - Rear mechanical components removed
The jig rests under the rear side member and is cen-
tred on tapped hole (B) .
Use this situation for a rear impact with removal of the
mechanical components.IV - SECONDARY REAR TRIM-SETTING
REFERENCE POINT
The jig rests under the rear side member and is positio-
ned in the hole (J) .
Use this situation to confirm the trim-setting following a
frontal impact (e.g.: to replace a complete front half
unit).
It is used to confirm the vehicle trim setting in case of
doubt about the deformation of a main front reference
point.
120609
121746
Note:
If it is suspected that one of these points may be
deformed, use two additional points located in an
area not affected by the impact in order to confirm
trim-setting.
121748

40A-7
GENERAL INFORMATION
Subframe: Specifications
40A
Description X Dimen-
sion YDimen-
sion ZDiameterAngle (in
degrees)
AFront subframe rear mounting,
without mechanical components205 402.5 71
Front sub-frame rear mounting with
mechanical components205 402.5 38
B1Rear axle assembly front moun-
ting, without mechanical compo-
nents1906 -530 129
Rear axle assembly front moun-
ting, with mechanical components1906 -530 126
BRear axle leader pin without
mechanical components1934 -530 129
CFront left-hand mounting of front
sub-frame without mechanical
components-385 -447 130
Front left-hand mounting of front
sub-frame with mechanical compo-
nents-385 -447 125
Front right-hand mounting of front
sub-frame without mechanical
components-385 465 130
Front right-hand mounting of front
sub-frame with mechanical compo-
nents-385 465 125
ERear shock absorber upper moun-
ting2342 -535 477.5 18.2
FFront shock absorber upper moun-
ting18.5 -545.5 657 48 X: 3.02˚
Y: 1˚
GRear section of front left-hand side
member600 -375 -3.7
GdRear section of front right-hand
side member600 351.6 -5
JRear side member rear leader pin 2858 -481 162.5 10.2
KFront cross member -578.5 277.6 275.7 6
PEngine front mounting -247 483.5 514
QEngine rear mounting -113 483.5 514

40A-8
GENERAL INFORMATION
Subframe: Specifications
40A
121743

40A-9
GENERAL INFORMATION
Hollow section inserts: List and location of components40A
DETAILED VIEW OF THE POSITION OF HOLLOW
SECTION INSERTS ON THE VEHICLE
A-pillar insert (1) .A-pillar reinforcement insert (2) .
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121243
121244

40A-10
GENERAL INFORMATION
Hollow section inserts: List and location of components40A
Rear wing panel insert (3) .
121242

40A-11
GENERAL INFORMATION
Hollow section inserts: Precautions for the repair
40A
The expanding inserts ensure that the vehicle cavities
are sealed and soundproofed. They react to the tempe-
rature when the bodywork is immersed in the catapho-
retic bath at the factory. These conditions cannot be
reproduced on the bodywork.
As inserts are not recoverable, always replace expan-
ding inserts.
The inserts supplied by the Parts Department are
identical to the original parts.
To obtain the same sealing and soundproofing proper-
ties, carry out the following operations:
-clean the bonding surfaces with heptane,
-if necessary, block the holes in the insert using pieces
cut from a soundproofing pad.
-apply a bead of preformed trim sealing mastic around
and inside the insert holes,
-fit the insert by compressing the mastic.
In some cases, it is possible to replace the accessible
part of the insert only, which must be cut out of the re-
placement part.WARNING
Do not refit the part after compressing the bead.
When EGW welding, protect the inserts from spat-
ter and heat dispersion.
For example, use a heat shield.