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Renault Clio Cup User Manual Download Page 64

Anti-roll bar tie-rod mounting bolts 

44 

 

Point H nut 

37 

 

Anti-rotation tie-rod mounting bolt on 

wishbone 

100 

 

Anti-roll bar 

 

 

Bearing mounting bolts on subframe  

21 

 

Anti-roll bar tie-rod nut 

44 

 

REAR AXLE 

 

 

Wheel  

 

Wheel bolt 

110 

 

Hub  

 

Spindle nut 

220 

 

Damper system 

 

 

Upper mounting bolt 

80 

 

Lower mounting bolt 

105 

 

Rear axle 

 

 

Bearing mounting bolt on body 

62 

 

Nut for bearing mounting bolt on rear axle 

125 

 

Plate spindle on axle 

71 

 

Brake hose nut 

14 

 

STEERING  

 

Axial ball joint 

 

 

Axial ball joint 

50 

 

Point H ball joint  nut 

37 

 

Wheel alignment  locknut 

53 

 

Steering unit 

 

 

Steering unit mounting on subframe 

105 

 

Folding yoke cam bolt 

24 

 

Steering column 

 

 

Column mounting bolt on roll cage 

crossmember 

105 

 

Sheath bolt 

21 

 

Sheath mounting bolt on roll cage stays 

21 

 

Intermediate shaft mounting bolt on column 

34 

 

Wheel hub bolt 

44 

 

Summary of Contents for Clio Cup

Page 1: ...USER MANUAL E Chassis...

Page 2: ...Y VARIATIONS 24 4 3 3 ADJUSTMENT OF GEOMETRY 25 4 3 4 REAR LOAD BEARING COMPONENTS 26 4 4 STEERING 29 4 4 1 STEERING UNIT 29 4 4 2 INTERMEDIATE SHAFT 33 4 4 3 STEERING COLUMN 34 4 4 4 ELECTRIC POWER S...

Page 3: ...Castor angle Pivot Spring Stop Rear right wheel Rear left wheel Camber Stop Alignment opening Camber Tyre pressure when warm Alignment opening Castor angle Wheel base Pivot Spring Front right wheel Ca...

Page 4: ...TERISTICS The front axle is a double axis strut type suspension system Anti rotation tie rod Point F Pivot pivot holder l QQ tie rod Point P Anti roll bar bearing Point P Point F Upper shock absorber...

Page 5: ...lease E 5 Point E EE support Anti roll bar tie rod Support strut Pivot Damper system z axis y axis Point E bolt Pivot holder Caliper Point F Pivot to pivot holder mounting ball joint Roller bearing Di...

Page 6: ...ng 75N mm Bump stop length 35mm diameter 34mm Damping The shock absorbers are not adjustable they must not be opened They are provided with seal paint The lack of or damage to this paint can be consid...

Page 7: ...of fuel in the tank With new or identically worn tyres Tyre pressure at 2 bars Measuring the front body height The front body height is measured at the level of the lower front wishbone mounting 1 Mea...

Page 8: ...Front axle diagnostics Incident Possible cause s Faulty castor angle Distorted wishbone Distorted side member or subframe axle Camber pivot correct overall but Individual faulty camber Individual pivo...

Page 9: ...r height mm Compression Rebound Per wheel camber variation 3 65 3 6 3 55 3 5 3 45 3 4 3 35 3 3 3 25 3 2 3 15 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 Suspension travel mm 0mm for 110 mm body height C...

Page 10: ...means of the steering tie rod 1 Loosen the locknut 2 Adjust the alignment by tightening or loosening the steering tie rod One the required setting achieved tighten the locknut to 53Nm Camber Adjust t...

Page 11: ...Photos 1 Remove the wheel 2 Remove the upper mounting nut 2 of the anti roll bar tie rod 3 Remove the support strut mounting bolt 1 on the pivot holder 4 Extract the pivot holder support strut 5 Attac...

Page 12: ...pring cup 3 6 Remove the suspension spring 4 7 Unscrew the support strut shock absorber rod Reassembly Operations 1 Thoroughly clean the inside of the support strut and shock absorber cartridge 2 Repl...

Page 13: ...t H 4 7 Remove the wheel speed sensor at the level of the pivot 8 Remove the support strut mounting bolt 2 on the pivot holder 9 Extract the pivot holder support strut 10 Remove the pivot holder pivot...

Page 14: ...3 6 Remove the EE support Refitting Perform the removal steps in reverse order Tightening torques Point E mounting bolt 26 5Nm 3 pivot holder mounting bolts 105Nm Point E nut 105Nm Wishbone Removal O...

Page 15: ...nut 105Nm Wishbone point A bolt 80Nm Wishbone point B bolt 80Nm Wishbone ball joints In case of replacement the new part must be fitted in the same position the shoulder area of the A casing must rest...

Page 16: ...ected to the steering unit 2 Remove the connecting torque rod 3 Place a hydraulic plate in contact under the subframe 4 Remove the wheel speed sensors 2 at the level of the pivots and disconnect them...

Page 17: ...level of the support struts 7 10 Disconnect the QQ tie rods at the body level 8 11 Remove the bolts from points P 9 and P 10 12 Extract the subframe by lowering the hydraulic plate Preparing the subfr...

Page 18: ...me reinforcement plate as below 1 Drill a 25 to 30 mm hole below the draining stopper of the differential casing 2 Carry out a clearing around the screw head to allow the access of a 6 sides bushing 1...

Page 19: ...Connecting torque rod mounting bolt on subframe 105Nm Anti roll bar Removal Operations Photos 1 Remove the anti roll bar tie rod mounting nuts 1 at the level of the anti roll bar 2 Remove the subframe...

Page 20: ...2010 Release E 20 4 2 6WHEEL PASSAGES The wheel passages are in 2 parts a rear one and a front one 1 Cut out the rear wheel passages like on the photograph 2 Fit the wheel passages...

Page 21: ...erse order to remove it 3 Fix the plastic mounting clamps right side on photograph 4 Tight this 3 screws behind the wheel under the protective moulding 5 Fix a plastic collar between the front wheel p...

Page 22: ...4 3 REAR AXLE 4 3 1PRESENTATION AND CHARACTERISTICS The rear axle has combined swingshafts Caliper Axle Shock absorber mounting bolt Hub carrier Disc Bearing mounting bolt on Bearing Mounting bolt on...

Page 23: ...er 31mm Damping The shock absorbers are not adjustable they must not be opened They are provided with seal paint The lack of or damage to this paint can be considered as a technical non compliance Eff...

Page 24: ...er height mm Rebound Compression Per wheel camber variation 2 08 2 06 2 04 2 02 2 1 98 1 96 1 94 1 92 1 9 60 50 40 30 20 10 0 10 20 30 40 50 60 70 80 90 Suspension travel mm 0 mm for 110 mm body heigh...

Page 25: ...hickest edge The correspondence between the shims and their resulting alignment camber is given in the following table Camber shim Alignment shim No shim 10 77 11 160 176 20 77 11 160 175 30 77 11 160...

Page 26: ...Operations Photos 1 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 5 Remove the damper system Refitti...

Page 27: ...hotos 1 Place the vehicle on an auto lift 2 Remove the lower attachment 1 of the two shock absorbers 3 Remove the brake hoses from the calipers 4 Support the rear axle and then remove The six bearing...

Page 28: ...ect 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 Follow spacer assembly direction 2 lon...

Page 29: ...l joint is replaced with the steering unit in place on the vehicle Indeed the Dir 1741 or Dir 1305 01 tool is used to connect the bar to the steering unit To avoid damaging the pinion teeth and steeri...

Page 30: ...he small bellows clamp 1 7 Cut the large bellows clamp 2 8 Unscrew the steering tie rod counter clockwise and note the number of rotations for refitting 9 Remove the steering tie rod 10 Extract the be...

Page 31: ...s see 4 4 Steering Steering unit Bellows Follow the ball joint unit markings one mark on the right 1 and 2 on the left 2 Left ball joint unit Right ball joint unit Tightening torques Axial ball joint...

Page 32: ...nents Subframe Bellows Bellows assembly When replacing an axial ball joint new bellows MUST be refitted To ensure the good air balance the steering MUST be placed at the mid point 1 Fit a nose cone on...

Page 33: ...8 on the column 6 Remove the intermediate shaft 9 Refitting Perform the removal steps in reverse order Systematically replace the folding yoke bolt ref 77 03 602 097 and cam nut after each removal Not...

Page 34: ...e bell from the folding yoke 1 7 Remove the 2 roll cage stay bolts 2 on the steering sheath 8 Remove the 2 sheath mounting bolts 3 on the column 9 Remove the column sheath 10 Remove the extinguisher j...

Page 35: ...m 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 7 Place the steering wheel hub on the column 8 Tighten the hub mo...

Page 36: ...e necessary to check the unit s temperature before disassembling it Use Start up Ensure that the EPS is correctly connected to the wiring harness Turn on the vehicle s electrics button 12 on the contr...

Page 37: ...rking order If the system is still malfunctioning after these checks it must be immediately returned to the Alpine after sales service Symptom 2 When the steering wheel is turned the power steering st...

Page 38: ...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 Refittin...

Page 39: ...Disc diameter 312mm Disc thickness 28mm Minimum disc thickness 26mm Rear brake Clutch slave cylinder diameter 38mm Disc diameter 300mm Disc thickness 11mm Minimum disc thickness 9 5mm Master cylinder...

Page 40: ...mference of the pad if the discs are hollowed Perform 3 to 4 medium pressure braking operations 150 to 100kph Allow to cool between braking 400 meters Perform 1 heavy pressure braking operation 180 to...

Page 41: ...k the pistons Watch out for rising brake fluid levels in the tank 2 Remove the upper spindle 1 using a drift punch 3 Remove the spring and lower spindle 2 4 Remove the pads noting their position for r...

Page 42: ...systematically replaced Removal Operations Photos 1 Disconnect the banjo bolt 1 linking the hose to the caliper brake fluid will pour out 2 Remove the brake pads see previous paragraph 3 Remove the t...

Page 43: ...h it in the wheel arch Do not damage the hose 1 4 Remove the two disc mounting bolts 3 5 Remove the track shim and the disk Refitting Operations 1 Fit the disc onto the hub 2 Fit the track shim ref 77...

Page 44: ...lumn mountings 3 Swivel the calipers upwards 4 Remove the brake pads Refitting Operations Photos 1 Check pad thickness 2 Clean the caliper supports and the calipers 3 Push caliper piston back into its...

Page 45: ...up 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 Removal Operations Photos 1 Remove th...

Page 46: ...liper 5 Refit the new small column bolts 6 Refit the brake hose 7 Tightening torques Small column bolts 32Nm Brake hose 14Nm Hub disc Removal Operations Photos 1 Release the spindle bolt 1 2 Remove th...

Page 47: ...d tighten the bolts to 105Nm 4 Refit the pads see corresponding paragraph 5 Refit the wheel and tighten the bolts to 130Nm 6 Tighten the spindle nut to 220Nm 7 Press the brake pedal several times in o...

Page 48: ...mpliant with the 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 fr...

Page 49: ...he 2 master cylinder mounting bolts 4 on the amplifier 6 Remove the master cylinder tank assembly 7 Remove the master cylinder tank mounting bolt 5 8 Remove the master cylinder tank Refitting Perform...

Page 50: ...r box and intake pipe 2 Remove the check valve at the amplifier lever 1 3 Remove the master cylinder see previous paragraph 4 Remove the dual safety coupling shaft 5 between the braking amplifier thru...

Page 51: ...lace the coupling shaft ref 82 00 420 641 between the braking amplifier thrust rod and the brake pedal Ensure it is locked Check valve Removal Operation Photo 1 Disconnect the check valve from the bra...

Page 52: ...ng circuit and depending on the setting the rear circuit pressure is limited to between 10 and 40 bars Wastegate operating curve Note The front rear pressure distribution can be displayed on the Brake...

Page 53: ...ations Photos 1 Fit the wastegate on the support using the two bolts 2 2 Place the connector ends in the wastegate s threaded holes Initiate threading manually Note Follow the direction of assembly 3...

Page 54: ...The tyres are made by Michelin Dry Wet Front S9C P2E Type Rear S9C P2E Front 20 61 17 20 61 17 Dimensions Rear 20 61 17 20 61 17 Front 1 6 1 7 Cold inflation pressure bar Rear 1 7 1 8 The cold pressu...

Page 55: ...per support 77 11 162 543 1 Left halogen headlight 77 11 162 544 1 Right halogen headlight 77 11 162 545 1 Black superior bumper trim cover 77 11 162 546 1 Black inferior bumper trim cover F1 blade 77...

Page 56: ...lue If you do not have a press a vice should be sufficient Fit the snap ring 77 11 128 850 Repeat this procedure for the 3 other ball joints WARNING Without either heating the casing or cooling the ba...

Page 57: ...d ones Use the fasteners of the old ones 2 x 3 screws Fit the shell mirror pulled down 4 7 4DIFFUSER Fit the external nozzles 77 11 162 534 on the diffuser Fit the ducts 77 11 162 533 using the 6 scre...

Page 58: ...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 Fasteners are the same as the ones used for the old one new...

Page 59: ...t the headlight to the front wiring loom The connector of the left headlight is reversed compared to the old one 4 7 6FRONT BUMPER Get back the 3 fences of the old bumper Fit the towing hook Fit the R...

Page 60: ...vets 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 th...

Page 61: ...sing 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...

Page 62: ...it 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...

Page 63: ...0 Support strut mounting bolt on pivot holder 105 Pivot holder Point E nut 105 Bolt class 12 9 EE support Mounting bolt on pivot holder 140 Ball joint E mounting bolt 26 5 Wishbone Point A bolt 80 Poi...

Page 64: ...Rear axle Bearing mounting bolt on body 62 Nut for bearing mounting bolt on rear axle 125 Plate spindle on axle 71 Brake hose nut 14 STEERING Axial ball joint Axial ball joint 50 Point H ball joint n...

Page 65: ...ose banjo bolt 14 Bleed screw 5 to 8 Front disc Disc bolt 21 Rear brake caliper Brake caliper mounting bolt on axle 105 Brake hose nut 14 Rear disc Spindle nut 220 Master cylinder Mounting bolt on bra...

Page 66: ...nt E 26 5 6 Pivot ball joint nut on pivot holder point F 140 7 Support strut bolt on pivot holder 105 8 Point F plate bolt on body 100 9 Upper shock absorber nut 105 10 Anti rotation tie rod mounting...

Page 67: ...t on tie rod 44 15 Anti roll bar bearing bolts on subframe 21 16 Steering unit mounting bolt on subframe 24 17 QQ tie rod bolt on subframe 80 18 QQ tie rod bolt on body 105 19 Reinforcement plate moun...

Page 68: ...cific recommendations 1 Spindle nut 220 2 Hub carrier bolt on axle 71 3 Small column bolt 32 4 Bearing mounting bolt on body 62 5 Lower shock absorber mounting bolt 105 6 Brake hose nut 14 7 Nut for b...

Page 69: ...orque in Nm Specific recommendations 1 Folding yoke cam bolt 24 2 Column mounting bolt on roll cage crossmember 105 3 Sheath bolt 21 4 Sheath mounting bolt on roll cage stays 21 5 Intermediate shaft m...

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