Renault Clio Cup User Manual
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Renault Clio Cup User Manual

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E. Chassis

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  • Page 1 USER MANUAL E. Chassis...

  • Page 2: Table Of Contents

    2010 Release 4 CHASSIS CONTENTS 4 CHASSIS SETUP FRONT AXLE 4.2.1 PRESENTATION AND CHARACTERISTICS 4.2.2 GEOMETRY INSPECTION 4.2.3 GEOMETRY VARIATIONS 4.2.4 ADJUSTMENT OF GEOMETRY 4.2.5 FRONT LOAD-BEARING COMPONENTS 4.2.6 WHEEL PASSAGES REAR AXLE 4.3.1 PRESENTATION AND CHARACTERISTICS 4.3.2 GEOMETRY VARIATIONS 4.3.3 ADJUSTMENT OF GEOMETRY 4.3.4...

  • Page 3: Setup

    2010 Release 4.1 SETUP The following Clio Cup settings apply with a 70kg driver and 40kg of fuel on board. CLIO CUP 2009 BASIC SETTINGS Front track 1,528mm Body height at front 110mm Front anti-roll bar 22mm Front left wheel...

  • Page 4: Front Axle

    2010 Release 4.2 FRONT AXLE 4.2.1 PRESENTATION AND CHARACTERISTICS The front axle is a double axis strut type suspension system. Anti-rotation tie- QQ’ tie-rod Point A Anti-roll bar Point F’: Pivot/pivot- holder Point H Point B Point F: Upper shock absorber mounting Point P Anti-roll bar...
  • Page 5 2010 Release Damper system z-axis y-axis Anti-roll Support bar tie-rod strut Pivot Pivot holder Point E’ bolt EE’ support Point E Point F’: Roller bearing Pivot to pivot holder mounting ball joint Caliper Disk...
  • Page 6 2010 Release Hinges  Wishbones (6): • Subframe side: by ball joint link. • Wheel side: by ball joint link.  Upper pivot and shock absorber: by ball joint link. Suspension  Suspension spring: 75N/mm.  Bump stop • length: 35mm, •...

  • Page 7: Geometry Inspection

    2010 Release 4.2.2 GEOMETRY INSPECTION Body height measurement points Conditions Body height measurement is performed:  With the driver on board. Front Rear  On a flat surface. body body  With 50L of fuel in the height height tank. ...
  • Page 8 2010 Release Angle inspection Preliminary checks Before checking the axle angles, check (and correct if necessary) the following points:  Tyre symmetry on a given axle: • Pressure • Wear  Hinges: • Condition of flexible bearings • Ball joint clearance •...

  • Page 9: Geometry Variations

    2010 Release 4.2.3 GEOMETRY VARIATIONS Roll center height variation C ompression Rebound Suspension travel (mm) 0mm for 110 mm body height Per-wheel camber variation -3,15 -35 -30 -25 -20 -15 -10 -3,2 -3,25 -3,3 -3,35 C ompression Rebound -3,4 -3,45 -3,5 -3,55 -3,6...

  • Page 10: Adjustment Of Geometry

    2010 Release 4.2.4 ADJUSTMENT OF GEOMETRY Body height Body height is adjusted using the nut (1) mounted on the support strut. Loosen the locknut (2). Adjust body height tightening loosening the nut. Once the required height has been reached, tighten the locknut. Wheel alignment Adjust the clip by means of the steering tie-rod (1).

  • Page 11: Front Load-Bearing Components

    2010 Release 4.2.5 FRONT LOAD-BEARING COMPONENTS Support strut Since 2009 february the 1 , the damper tube 77 11 160 015 has been replaced by a new reference 77 11 162 518 The mechanicals characteritics of the material and the shape of the part have been modified to avoid plastic deformation of the damper tube Remarque= these geomatrical modifications don’t have any incidence on the car behaviour...
  • Page 12 2010 Release Disassembly Operations Photos Remove the upper nut, holding the shock absorber with a hexagonal socket wrench. 2 - Remove the snap ring (1). Loosen the nut (5) and locknut (6) so that the spring is relaxed (3). Remove the retainer ring (2) from the spring cup.
  • Page 13 2010 Release Pivot holder Removal Operations Photos 1 - Remove the wheel. Remove the brake caliper (see 4-5 Brake system/Front brakes/Calipers) and attach it in the wheel arch. 3 - Remove the point E nut (1). Extractsupport EE' from the point E ball joint; a ball joint puller must be used to do this.
  • Page 14 2010 Release EE’ support Removal Operations Photos 1 - Remove the wheel. 2 - Remove the point E nut (1). Extract the EE' support from the point E ball joint; a ball joint puller must be used to do this. 4 - Remove the point E’...
  • Page 15 2010 Release Refitting Perform the removal steps in reverse order. Check front axle geometry and adjust if necessary. Note: The wishbone mounting bolts on the subframe should be tightened when the vehicle is completely static. Tightening torques:  Point E nut: 105Nm. ...
  • Page 16 2010 Release Subframe Removal Operation Photos Remove the intermediate shaft (see 4-4 Steering/Intermediate shaft). Note: Do not turn the wheel when the shaft is not connected to the steering unit. 2 - Remove the connecting torque rod. Place a hydraulic plate in contact under the subframe.
  • Page 17 2010 Release Disconnect the anti-rotation tie-rods at the level of the wishbones (5). Disconnect the steering tie-rods at the level of points H (6). Disconnect the anti-roll bar tie-rods at the level of the support struts (7). Disconnect the QQ’ tie-rods at the body level 10 - (8).
  • Page 18 2010 Release Steering unit mounting bolt ref.: 77 03 602 136 Steering unit ref.: 77 11 160 046 Steering unit riser shims ref.: 77 11 160 016 To allow : The differential casing-oil change, An access to the fixation screw of the rear powertrain support rod: It is allowed to modify the subframe reinforcement plate as below, 1) Drill a ø...
  • Page 19 2010 Release Refitting Perform the removal steps in reverse order. Tightening torques:  Bolts for points P and P’: 120Nm.  QQ’ mounting bolts to body: 105Nm.  Anti-roll bar tie-rod mounting bolt: 44Nm.  Point H nut: 37Nm.  Anti-rotation tie-rod mounting bolt on wishbone: 100Nm. ...

  • Page 20: Wheel Passages

    2010 Release 4.2.6 WHEEL PASSAGES The wheel passages are in 2 parts, a rear one and a front one. Cut out the rear wheel passages like on the photograph Fit the wheel passages E-20...
  • Page 21 2010 Release Fix the plastic mounting clamps (right side on photograph) Tight this 3 screws under the protective moulding behind the wheel Fix a plastic collar between the front wheel passage and the plastic plate for engine protection Perform the assembly steps in reverse order to remove it. E-21...

  • Page 22: Rear Axle

    2010 Release 4.3 REAR AXLE 4.3.1 PRESENTATION AND CHARACTERISTICS The rear axle has combined swingshafts. Caliper Disc Bearing Hub carrier mounting bolt on Shock absorber mounting bolt Axle Bearing Mounting bolt on rear axle (point A) E-22...
  • Page 23 2010 Release Hinges  Lower: by ball joint.  Upper (shock absorber): by ball joint. Suspension  Suspension spring: 130N.  Bump stop: • length: 50mm • diameter: 31mm. Damping The shock absorbers are not adjustable, they must not be opened. They are provided with seal paint.

  • Page 24: Geometry Variations

    2010 Release 4.3.2 GEOMETRY VARIATIONS Roll center height variation C ompression Rebound Suspension travel (mm) 0 mm for 110 mm body height Per-wheel camber variation -1,9 -50 -40 -30 -20 -1,92 -1,94 -1,96 -1,98 C ompression Rebound -2,02 -2,04 -2,06 -2,08 Suspension travel (mm) 0 mm for 110 mm body height...

  • Page 25: Adjustment Of Geometry

    2010 Release 4.3.3 ADJUSTMENT OF GEOMETRY Body height Body height is adjusted using the nut (1) mounted on the extension (2). Loosen the locknut (3). Adjust body height tightening loosening the nut. Once the required height has been reached, tighten the locknut. Alignment and camber The alignment and camber of the rear axle are adjusted by inserting shims (1) between the...

  • Page 26: Rear Load-Bearing Components

    2010 Release 4.3.4 REAR LOAD-BEARING COMPONENTS See 4-5 Brake System/Rear brakes/Hub disc. Damper system Removal Operations Photos Place the vehicle on a jack stand on the appropriate side. 2 - Remove the wheel. 3 - Remove the lower mounting bolt (1). 4 - Remove the upper mounting nut (2).
  • Page 27 2010 Release Disassembly & reassembly The disassembly & reassembly of the damper system is performed in the same manner as for the front axle (see 4-3 Front axle/Front load bearing components/Support strut). Rear axle Removal Operations Photos 1 - Place the vehicle on an auto-lift. Remove the lower attachment (1) of the two shock absorbers.
  • Page 28 2010 Release Disassembly Operations Photo Remove the point A bolt (1) and collect the spacers (2). 2 - Remove the snap ring. 3 - Remove the ball joint from point A (3). Reassembly Perform the removal steps in reverse order. Tighten the bolt (1) to 125Nm.

  • Page 29: Steering

    2010 Release 4.4 STEERING Power steering module Steering Steering tie-rod ball column joint Intermediate shaft Folding yoke Steering tie- Steering unit Bellows 4.4.1 STEERING UNIT Axial ball joint Specialist tools  Dir. 1305-01 Axial ball joint removal-refitting tool.  Dir. 1741 Steering unit bar retainer tool.
  • Page 30 2010 Release Removal Operations Photos 1 - Place the vehicle on an auto-lift. Remove the front wheel on the relevant side. 3 - Loosen the alignment locknut (1). 4 - Remove the point H nut (2). Extract the ball joint from point H using the tool: (1) Tav.
  • Page 31 2010 Release Minimum thread installation: 1.5 times the thread diameter, i.e. 18mm of thread engaged in the ball joint sleeve. Perform the removal steps in reverse order. Note: Position the steering unit shim (Ref 77 11 160 142) before fitting the axial ball joint onto the steering unit.
  • Page 32 2010 Release Refitting Operations 1 - Position the riser shims on the subframe (ref 77 11 160 016, thickness: 5mm). 2 - Fit the steering unit on the subframe. 3 - Tighten the two bolts to 105Nm. 4 - Refit the subframe (see 4-4 Front axle/Front load bearing components/Subframe). Bellows Bellows assembly When replacing an axial ball joint, new bellows MUST be refitted.

  • Page 33: Intermediate Shaft

    2010 Release 4.4.2 INTERMEDIATE SHAFT Removal Operations Photos 1 - Remove the folding yoke bell (1) (discard). 2 - Set the wheels straight. 3 - Remove the folding yoke bolt (7) (discard). 4 - Remove the folding yoke nut (discard). Remove the intermediate shaft bolt (8) on the column.

  • Page 34: Steering Column

    2010 Release 4.4.3 STEERING COLUMN Removal Operations Photo Set the vehicle wheels straight. Disconnect the battery's ground cable. Remove the dashboard. Disconnect the power steering wiring harness. Remove the steering wheel, followed by the wheel hub, after marking their initial positions. Extract the bell from the folding yoke (1).
  • Page 35 2010 Release Refitting 1 - Refit the steering column. 2 - Tighten the four bolts to 105Nm. 3 - Fit the folding yoke. 4 - Tighten the cam nut to 24Nm. 5 - Fit the sheath onto the column and tighten the 2 bolts to 21Nm. 6 - Tighten the 2 roll cage stay mounting bolts on the column to 21Nm.

  • Page 36: Electric Power System

    2010 Release 4.4.4 ELECTRIC POWER SYSTEM If the unit undergoes a heavy impact or if the vehicle is involved in an accident. The unit MUST be sent to the Alpine after-sales service. Transport precautions The unit must be held in place by the shaft and engine housing. Handling the unit using the shaft alone can cause significant damage to the torque sensor and, consequently, can lead to unit malfunction.
  • Page 37 2010 Release Power off Before switching off completely, the system switches to “power latch” mode. During this phase, the system checks the operation of certain components that cannot be tested during the operating phase. To ensure that all the tests are performed correctly, power must be maintained for at least 30 seconds after dashboard shutdown (wait 30 seconds between turning off the engine: using switch (12) before cutting off the general power supply with switch (1)).
  • Page 38 2010 Release Removal Operations Photo Remove the steering column (see previous paragraph). Remove the 4 unit mounting bolts (1) on the steering column. Remove the power steering module from the column. Note: keep the four spacers. It is important not to run the EPS unit when the column has been removed in order to not offset the position sensor (see 4-4 Steering/EPS unit).

  • Page 39: Braking System

    2010 Release 4.5 BRAKING SYSTEM 4.5.1 CHARACTERISTICS Front brake  Clutch slave cylinder diameter: 40mm.  Disc diameter: 312mm.  Disc thickness: 28mm.  Minimum disc thickness: 26mm. Rear brake Clutch slave cylinder diameter: 38mm.  Disc diameter: 300mm.  Disc thickness: 11mm.
  • Page 40 2010 Release Clio Cup is only officially approved by Renault Sport when fitted with Ferodo brake pads. Running in Ferodo DS 1.11 brake pads do not require any specific running-in. DS 2500 brake pad run-in protocol:  Clean the brake disc with Emery paper (surface in contact with the pad).

  • Page 41: Front Brakes

    2010 Release 4.5.2 FRONT BRAKES Brake pads Removal Operations Photos Push back the pistons. Watch out for rising brake fluid levels in the tank. Remove the upper spindle (1) using a drift punch. 3 - Remove the spring and lower spindle (2). Remove the pads, noting their position for refitting, where appropriate.
  • Page 42 2010 Release Maximum authorized contact surface with the disc The maximum front brake pad friction material surface area tolerated on the Clio Cup is shown on the following diagram. Brake calipers The brake calipers cannot be repaired. If a fault is detected on the caliper, it must be systematically replaced.
  • Page 43 2010 Release Disk Removal Operations Photos Push back the pistons. Watch out for rising brake fluid levels in the tank. Remove the two bolts (2) holding the caliper on the pivot. Release the caliper and attach it in the wheel arch. Do not damage the hose (1).

  • Page 44: Rear Brakes

    2010 Release 4.5.3 REAR BRAKES Brake pads Specialist tools:  Fre 1190-01 Brake caliper piston driver. Removal Operations Photos 1 - Remove the wheels. 2 - Remove the lower small column mountings. 3 - Swivel the calipers upwards. 4 - Remove the brake pads. Refitting Operations Photos...
  • Page 45 2010 Release Maximum authorized contact surface with the disc The maximum rear brake pad friction material surface area tolerated on the Clio Cup is shown on the following diagram. Brake calipers The brake calipers cannot be repaired. If a fault is detected on the caliper, it must be systematically replaced.
  • Page 46 2010 Release Refitting Operations 1 - Check the condition of the caliper piston bellows. 2 - Clean the caliper support and the caliper. 3 - Refit the brake pads (see 4-5 Braking system/Rear brakes/Pads). 4 - Refit the caliper. 5 - Refit the new small column bolts. 6 - Refit the brake hose.
  • Page 47 2010 Release Refitting Operations 1 - Fit the hub. disc (1) on the spindle. 2 - Position the spindle bolt. 3 - Refit the brake caliper and tighten the bolts to 105Nm. 4 - Refit the pads (see corresponding paragraph). 5 - Refit the wheel and tighten the bolts to 130Nm.

  • Page 48: Braking Circuit

    SAE J 1703 dot 5 standard should be used. Recommended brake fluid: RENAULT ref. 77 01 422 979 (0.5L bottle). Bleeding Drainage should be performed starting with the caliper furthest away from the master cylinder and ending with the nearest.
  • Page 49 2010 Release Master cylinder Removal Operations Photos Remove the air box (1) and intake pipe (2). Drain the master cylinder tank with a syringe. Remove the clutch master cylinder pipe (3). Remove the brake pipes, taking care to catch any brake fluid discharge. Remove master cylinder...
  • Page 50 2010 Release Braking amplifier The brake booster cannot be repaired. Maintenance operations are only allowed on the following parts:  Air filter  Check valve Removal Operations Photos 1 - Remove the air box and intake pipe. Remove the check valve at the amplifier lever (1).
  • Page 51 2010 Release Refitting Perform the removal steps in reverse order. Tighten the amplifier and spacer bolts to 21Nm. Check the dimension L = 171mm, adjustable using the rod (C). Drain the braking circuit. Ensure that the braking amplifier gasket seal (11) is present and replace it if faulty.
  • Page 52 2010 Release Wastegate Operation The wastegatecan be adjusted by the driver from his seat:  Tighten the star wheel to increase rear braking,  Loosen the star wheel to reduce rear braking. Above a pressure of 10 bars in the braking circuit, and depending on the setting, the rear circuit pressure is limited to between 10 and 40 bars.
  • Page 53 2010 Release Removal Operations Photos Unscrew the connectors (1) (allow for brake fluid discharge). 2 - Remove the mounting bolts (2) and the wastegate. Refitting Operations Photos Fit the wastegate on the support using the two bolts (2). Place the connector ends in the wastegate’s threaded Output holes.

  • Page 54: Wheels And Tyres

    2010 Release 4.6 WHEELS AND TYRES 4.6.1 CHARACTERISTICS Wheels Material: Aluminum/magnesium alloy. Nominal  Width Wheel under tyre Number Wheel type ET offset (inches) profile bead holes (inches) 8J×17 Maximum offset: 0.3mm measured on the wheel rim. Maximum out-of-round: 0.3mm measured on the tyre bead bearing surface. When balancing the fitted wheels, it is essential to avoid placing the balancing weights in an area where they could come into contact with the EE’...

  • Page 55: Kit Evo 2009

    Black right rearview mirror shell 77 11 162 549 Left external rearview mirror 77 11 162 550 Right external rearview mirror 77 11 162 551 Assembled Renault ensign 77 11 162 565 FASTENERS Diffuser screw 77 03 017 090 Diffuser nut 77 03 034 276 Screw for diffuser’s duct...

  • Page 56: New Wishbone Mounting

    2010 Release 4.7.2 NEW WISHBONE MOUNTING The wishbones can only be purchased with their A and B casings already fitted. You only have to mount the ball joints 77 11 128 370 :  Fit the snap ring 77 11 162 563 in its groove (B casing) ...

  • Page 57: External Mirrors

    2010 Release 4.7.3 EXTERNAL MIRRORS The external mirrors directly take place instead of the old ones: Use the fasteners of the old ones (2 x 3 screws). Fit the shell, mirror pulled down. 4.7.4 DIFFUSER Fit the external nozzles 77 11 162 534 on the diffuser : Fit the ducts 77 11 162 533 using the 6 screws 77 03 008 211 and the 6 nuts 77 03 046 151 : ®...

  • Page 58: Front Headlights

    2010 Release Cut right the exit of the silencer tubes starting from the bottom of the genuine bevel : Recovering distance in the duct between 20 and 30 mm It is allowed to cut the screws in front of the duct to prevent from a possible contact with the silencer tubes : Fit the diffuser on the car.

  • Page 59: Front Bumper

    Get back the 3 fences of the old bumper. Fit the towing hook. Fit the Renault ensign using the 2 screws of the old ensign : Fit the plastic central fence 77 11 162 536 on the bumper. Fit the superior bumper trim cover on the bumper.
  • Page 60 2010 Release Fasten definitively the superior trim cover 77 11 162 546 using the 4 rivets 77 03 072 322 and the 2 plastic clips 77 03 072 361 : Rivets on superior face Plastic clip on inferior face Fit the inferior bumper trim cover 77 11 162 547 on the plastic central fence. Fasten the inferior trim cover using the 8 screws 77 03 017 101 : Fit the new aerodynamic blade (in 2 parts) on the bumper and fasten it definitely using 4 rivets 77 03 072 419 :...
  • Page 61 2010 Release Fit the deflector using the 10 rivets 77 03 072 419 : Fit the old central fence using plastic collars: Fit the 2 plastic retainers 82 00 700 969 on the front bumper: Fit the 2 old anti-fog light fences (glue, plastic collars or star rivets) on the anti- fog light covers : Fit these covers on the bumper.
  • Page 62 2010 Release Cut the inferior part of the towing hook plastic trap door: Fit the strap on the bumper using a velcro type fastener : It is forbidden to paint all parts in genuine shiny black paint. The anti-fog light and central fences are mandatory. NOTA : It is possible to use a standard rivet with a dished washer, in case you would not have any star rivet: E-62...

  • Page 63: Tightening Torques

    2010 Release 4.8 TIGHTENING TORQUES Tightening Specific Parts torques in Nm recommendations FRONT AXLE Wheels Wheel studs Copper grease Wheel nuts Wheel speed sensor 8 to 10 Drivetrain nut Damper system Upper shock absorber nut Point F plate bolt on body Support strut mounting bolt on pivot holder Pivot holder...
  • Page 64 Anti-roll bar tie-rod mounting bolts Point H nut Anti-rotation tie-rod mounting bolt on wishbone Anti-roll bar Bearing mounting bolts on subframe Anti-roll bar tie-rod nut REAR AXLE Wheel Wheel bolt Spindle nut Damper system Upper mounting bolt Lower mounting bolt Rear axle Bearing mounting bolt on body Nut for bearing mounting bolt on rear axle...
  • Page 65 2010 Release Electric power steering Module mounting bolt on steering column BRAKING SYSTEM Front brake caliper Brake caliper mounting bolt on pivot Brake hose banjo bolt Bleed screw 5 to 8 Front disc Disc bolt Rear brake caliper Brake caliper mounting bolt on axle Brake hose nut Rear disc Spindle nut...
  • Page 66 2010 Release Tightening Specific Parts torque in Nm recommendations Point A bolt Point B bolt EE’ support nut on wishbone Bolt class: 12.9 (point E) EE’ support bolt on pivot holder EE’ support bolts on pivot (point 26.5 E’) Pivot ball joint nut on pivot holder (point F’) Support strut bolt on pivot holder Point F plate bolt on body...
  • Page 67 2010 Release Tightening Specific Parts torque in Nm recommendations Anti-roll bar mounting bolt on tie- (14) Anti-roll bar bearing bolts on (15) subframe Steering unit mounting bolt on (16) subframe (17) QQ’ tie-rod bolt on subframe (18) QQ’ tie-rod bolt on body Reinforcement plate mounting bolt (19) on body (point P’)
  • Page 68 2010 Release Tightening Specific Parts torque in Nm recommendations Spindle nut Hub carrier bolt on axle Small column bolt Bearing mounting bolt on body Lower shock absorber mounting bolt Brake hose nut Nut for bearing mounting bolt on rear axle E-68...
  • Page 69 2010 Release Tightening Specific Parts torque in Nm recommendations Folding yoke cam bolt Column mounting bolt on roll cage crossmember Sheath bolt Sheath mounting bolt on roll cage stays Intermediate shaft mounting bolt on column E-69...

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