2009 RENAULT TWINGO RS engine

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

20A-12
CLUTCH
Clutch thrust bearing: Removal - Refitting
JB1
20A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the fork.
aRefit:
-the fork,
-the stop on the guide tube, placing the hooks (3)
into the fork.
aEnsure that it slides correctly.
III - FINAL OPERATION.
aRefit the gearbox (see 21A, Manual gearbox, Man-
ual gearbox: Removal - Refitting, page 21A-24) .aAfter refitting the gearbox, check the travel (X) of the
fork.
This must be:
-D4F engine: x = 29.5 mm ±± ± ±
0.5,
-D7F engine: x = 29.5 mm ±± ± ±
0.5.
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).
107916
Note:
During operations where the gearbox does not
have to be removed or refitted, do not lift the fork
because this may cause the hooks to come out
(3) of the thrust bearing.
91830

21A-2
MANUAL GEARBOX
Manual gearbox oils: Draining - Filling
JB1 or JH3 or JR5
21A
DRAINING
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the engine undertray.
aFit a oil recovery tray under the gearbox.
aRemove the drain plug (1) .
aLet the oil run into the oil recovery tray.
FILLING
aparts always to be replaced: mechanism hous-
ing drain plug seal.aRefit a new seal on the drain plug with the groove (2)
facing the plug.
aRefit the drain plug fitted with its new seal.
aRemove the filler cap (3) . Equipment required
oil recovery tray
Gearbox Capacity (l)
JB1 3.4
JH3 2.8
JR5 2.3
18749
113764
18749

21A-3
MANUAL GEARBOX
Manual gearbox oils: Draining - Filling
JB1 or JH3 or JR5
21A
aFill with the recommended oil to the level (4) of the
opening (see 21A, Manual gearbox, Manual gear-
box oil: Specifications, page 21A-1) (Technical
Note 6012A, 04A, Lubricants).
aRefit the filler cap.
aWipe any oil run-off with a cloth.
aRemove the oil recovery tray.
aRefit the engine undertray.
92081

21A-12
MANUAL GEARBOX
Manual gearbox: Identification
JH1 or JH3 or JR5
21A
K4J / K4M / K9K / D4F engines are fitted with type JH
and JR manual gearboxes.
A marking (1) on the gearbox casing indicates:
109167
19860
(A) Gearbox type
(B) Gearbox suffi x
(C) Production plant
(D) Production number

21A-24
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and JH3 or JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery).
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment).
aDisconnect the engine management computer con-
nectors.
aRemove:
-the engine management computer mounting bolts,
-the engine management computer mounting nuts.
aRemove the engine management computer mount-
ing.
aRemove the engine management computer wiring
harness nut from the engine management computer
mounting.
aRemove the engine management computer wiring
harness.
aRemove the engine management computer mount-
ing fitted with the engine management computer.aUnclip:
-the clutch hydraulic control pipe on the gearbox (1)
,
-the union (2) on the hydraulic tappet slave cylinder,
-the gearbox breather.
aRemove:
-the front left-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front left-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection).
aDrain the gearbox oil (see 21A, Manual gearbox,
Manual gearbox oils: Draining - Filling, page
21A-2) .
aRemove:
-the hub carrier - front left-hand and front right-hand
driveshaft assemblies (see ) (31A, Front axle com-
ponents),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting). Special tooling required
Mot. 1453Engine anchorage support
with m ultiple adjustments and
retaining str aps.
Equipment required
component jack
Tightening torquesm
lower gearbox bolts44 N.m
gearbox nuts and bolts44 N.m
gearbox upper bolts44 N.m
121410

21A-25
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K9K, and JH3 or JR5
21A
aLoosen the bolt (3) and the nut (4) on the upstream
strut of the catalytic converter on the gearbox.
aRemove:
-the bolt (5) from the upstream strut of the catalytic
converter on the catalytic converter,
-the upstream strut of the catalytic converter by slid-
ing it upwards,
-the starter (see Starter: Removal - Refitting)
(16A, Starting - Charging).
aFit the (Mot. 1453) :
-positioning it on the front wing opening stops and
on the headlight brackets,
-using the two engine lifting eyes to avoid the
« engine - gearbox » assembly tilting too much,
-making sure the tool is strapped to the vehicle.aRemove:
-the left-hand suspended engine mounting (see
Left-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting),
-the subframe (see Front axle subframe: Removal
- Refitting) (31A, Front axle components).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDetach the gearbox controls by pressing on the ca-
ble end pieces (6) .
aRemove the earth strap bolt.
aRemove the upper gearbox bell housing bolts.
aDisconnect:
-the speed and position sensor connector,
-the reverse gear switch connector.
aRemove:
-the lower gearbox bell housing bolts,
-the gearbox nuts,
-the gearbox studs.
aFit a component jack under the gearbox.
aRemove:
-the lower gearbox bell housing bolts,
-the gearbox.
106199
121415
108265

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