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Renault Clio Cup, Руководство пользователя, Страница: 4 / 69

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2010 Release 

 

 

 

 

E-4

 

 

4.2

 

FRONT AXLE 

 

 

4.2.1

 

PRESENTATION AND CHARACTERISTICS 

 

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 

mounting 

Point H 

 

Hub 

 

Point A 

 

Point B

 

x-

y-axis 

Anti-roll bar 

 

Содержание Clio Cup

Страница 1: ...USER MANUAL E Chassis...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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