Renault Clio Cup User manual

USER MANUAL
E. Chassis

2010 Release
E-2
4CHASSIS
CONTENTS
4CHASSIS 2
4.1 SETUP 3
4.2 FRONT AXLE 4
4.2.1 PRESENTATION AND CHARACTERISTICS 4
4.2.2 GEOMETRY INSPECTION 7
4.2.3 GEOMETRY VARIATIONS 9
4.2.4 ADJUSTMENT OF GEOMETRY 10
4.2.5 FRONT LOAD-BEARING COMPONENTS 11
4.2.6 WHEEL PASSAGES 20
4.3 REAR AXLE 22
4.3.1 PRESENTATION AND CHARACTERISTICS 22
4.3.2 GEOMETRY 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 SYSTEM 36
4.5 BRAKING SYSTEM 39
4.5.1 CHARACTERISTICS 39
4.5.2 FRONT BRAKES 41
4.5.3 REAR BRAKES 44
4.5.4 BRAKING CIRCUIT 48
4.6 WHEELS AND TYRES 54
4.6.1 CHARACTERISTICS 54
4.7 KIT EVO 2009 55
4.7.1 NEW WISHBONE MOUNTING 55
4.7.2 EXTERNAL MIRRORS 57
4.7.3 DIFFUSER 57
4.7.4 FRONT HEADLIGHTS 58
4.7.5 FRONT BUMPER 59
4.8 TIGHTENING TORQUES 63

2010 Release
E-3
4.1 SETUP
The following Clio Cup settings apply with a 70kg driver and 40kg of fuel on board.
1,528mm
110mm
22mm
-3°10'
-3°10'
-0°10'
53kg 53kg -0°10'
6°20' 6°20'
11°15' 317kg 317kg 11°15'
75N/mm
75N/mm
35mm
370kg 370kg 35mm
2
,
585mm 2.0 ba
r
-2°30'
-2°30'
38kg 38kg 0°10'
-
-
-
172kg 172kg -
130N/mm
130N/mm
50mm
210kg 210kg 50mm
1520mm
210mm
-
Castor angle
Pivot
Spring
Stop
Rear right wheel
Rear left wheel
Camber
Stop
Alignment
(+ opening)
Camber
Ty
re
p
ressure
when warm
Alignment
(+ opening)
Castor angle
Wheel base
Pivot
Spring
Front right wheel
Castor angle
Pivot
Stop
Stop
Body height at front
Front anti-roll bar
Unsprung mass
Front track
Camber
Camber
Front left wheel
Alignment
(
+ o
p
enin
g)
Alignment
(+ opening)
Spring
Spring
Castor an
g
le
Pivot
Rear track
Body height at rear
Rear anti-roll bar
T
otal mass
Sprung mass
Unsprung mass
T
otal mass
Sprung mass
CLIO CUP 2009 BASIC SETTINGS

2010 Release
E-4
4.2 FRONT AXLE
4.2.1PRESENTATION AND CHARACTERISTICS
The front axle is a double axis strut type suspension system.
Anti-rotation tie-
rod
Point F’:
Pivot/pivot-
holde
r
l
QQ’ tie-rod
Point P
Anti-roll bar
bearing
Point P
’
Point F:
Upper shock absorber
mountin
g
Point H
Hub
Point A
Point B
x-
y-axis
Anti-roll bar

2010 Release
E-5
Point E
EE’ support
Anti-roll
bar tie-rod
Support
strut
Pivot
Damper system
z
-
axis
y-axis
Point E’ bolt
Pivot holde
r
Calipe
r
Point F’:
Pivot to pivot
holder mounting
ball joint
Roller bearing
Disk
Hub

2010 Release
E-6
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,
• 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 considered
as a technical non-compliance.
Effect of shock absorber movement speed on stress
-200
-150
-100
-50
0
50
100
150
200
0
0.05
0.1
0.15
0.2
Speed
[
m/s
]
Force
[
daN
]
---- : Tolerance
: Nominal

2010 Release
E-7
4.2.2GEOMETRY INSPECTION
Body height measurement
points
- Conditions
Body height measurement is
performed:
 With the driver on
board.
 On a flat surface.
 With 50L 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).
- Measuring the rear body height
The rear body height is measured at the level of the rear axle point A bolt.
1
Ground projection
under subframe
Front
body
height
Rear
body
height

2010 Release
E-8
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
• Bearing clearance
 Wheel run-out (max. 0.3mm)
 Body and cup height symmetry
- 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 pivot wrong.
- Distorted wishbone
- Distorted side member or subframe-axle
Camber correct, but faulty pivot - Distorted pivot
Pivot correct, but faulty camber - Distorted pivot
Faulty variation in wheel alignment - Steering unit mounting on subframe
Wheel alignment off by more than 6mm - Distorted left or right-hand hub carrier

2010 Release
E-9
4.2.3GEOMETRY VARIATIONS
Roll center height variation
-80
-60
-40
-20
0
20
40
60
80
100
120
140
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
Suspension travel (mm)
0mm for 110 mm body height
Roll center 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
Camber (°)
Compression Rebound
Per-wheel alignment variation
-0,25
-0,2
-0,15
-0,1
-0,05
0
0,05
0,1
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
Suspension travel (mm)
0mm for 110 mm body height
Alignment (°)
ReboundCompression

2010 Release
E-10
4.2.4ADJUSTMENT OF GEOMETRY
Body height
Body height is adjusted using the nut (1)
mounted on the support strut.
Loosen the locknut (2).
Adjust body height by tightening or
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).
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 the camber by means of the upper
shock absorber mounting (point F).
Loosen the 3 plate bolts (1).
Adjust the camber.
Tighten the 3 bolts to 100Nm.
To avoid disconnecting the front left-hand drivetrain, driving with less than 3°
negative camber (more than -3°) on the front left-hand wheel is prohibited.
2
1
1
2
1

2010 Release
E-11
4.2.5FRONT LOAD-BEARING COMPONENTS
Support strut
Since 2009 february the 1st , 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
- Removal
Operations 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 -
Attach the pivot holder in the wheel arch to avoid
damaging the brake hose.
6 -
Remove the upper mounting nut (3).
7 -
Remove the fitted support strut.
- Refitting
Perform the operations in the reverse order of removal, taking care not to damage the
drivetrain bellows.
Tightening torques:
 Support strut mounting bolts on pivot holder (1):105Nm.
 Upper shock absorber nut (3):105Nm.
 Anti-roll bar tie-rod mounting nut on support strut (2): 44Nm.
1
2
3

2010 Release
E-12
- Disassembly
Operations Photos
1 -
Remove the upper nut, holding the shock
absorber with a hexagonal socket wrench.
2 -
Remove the snap ring (1).
3 -
Loosen the nut (5) and locknut (6) so that
the spring is relaxed (3).
4 -
Remove the retainer ring (2) from the
spring cup.
5 -
Remove the suspension spring 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 -
Replace the filters (ref 77 11 156 541) where necessary.
3 -
Position the bump stop (ref 77 11 160 290) on the shock absorber rod.
4 -
Lubricate the shock absorber cartridge with Bilstein grease (ref 77 11 126 744).
5 -
Proceed in reverse removal order.
6 -
Tighten the upper shock absorber nut to 105Nm.
1
2
4
5
6
3

2010 Release
E-13
Pivot holder
- Removal
Operations Photos
1 - Remove the wheel.
2 - 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).
4 - Extractsupport EE' from the point E ball joint; a
ball joint puller must be used to do this.
5 - Remove the anti-roll bar mounting nut from the
pivot holder(3).
6 - Disconnect the steering rod at the level of point
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 and EE’ support
assembly.
11 -
Remove the EE’ support (see following section)
12 -
Remove the nut from point F’.
13 -
Remove the pivot from the pivot holder using a
ball joint puller.
- Refitting
Perform the removal steps in reverse order.
Tightening torques:
 Support strut mounting bolt: 105Nm.
 Anti-rotation tie-rod nut: 100Nm.
 Point E nut : 105Nm.
 EE’ support mounting bolt on pivot holder: 105Nm.
 Point F' ball joint nut: 140Nm.
2
3
1
4

2010 Release
E-14
EE’ support
- Removal
Operations Photos
1 -
Remove the wheel.
2 -
Remove the point E nut (1).
3 -
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’ ball joint mounting bolt (2).
5 -
Remove the 3 EE’ support mounting bolts on the
pivot holder (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
Operations Photos
1 -
Remove the attachment (1) of the anti-roll bar
at the level of the wishbone.
2 -
Remove the point E nut (2).
3 -
Extract support EE' from the point E ball joint;
a ball joint puller must be used to do this.
4 -
Remove the two wishbone mounting bolts (3)
on the subframe.
5 -
Remove the wishbone.
2
3
1
3
2 1

2010 Release
E-15
- 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.
 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
on the wishbone machined surface (1).
In case of replacement, the new part must
be fitted in the same position: the shoulder
area of the B casing must rest on the
wishbone machined surface in order to
permit the fitting of the snap ring (1).
Front of vehicle
1
1

2010 Release
E-16
Subframe
- Removal
Operation Photos
1 - 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.
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 from
the support (3) on the steering tie-rod.
5 - Remove the point E nuts (4).
6 - Extract the EE' support from the point E ball
joint; a ball joint puller must be used to do
this.
2
3
4

2010 Release
E-17
7 - Disconnect the anti-rotation tie-rods at the
level of the wishbones (5).
8 - Disconnect the steering tie-rods at the level
of points H (6).
9 - Disconnect the anti-roll bar tie-rods at the
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 subframe before refitting
Do not forget the subframe braces and steering unit riser shims.
Aluminum
reinforcement plate
ref.
77 11
160 151
Bolt ref.:
77 11,156,911
+ washer
Spacer:
ref 77 11 160 184
6
8
5
7
9
10

2010 Release
E-18
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 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 (18mm)
Any other modification is not allowed
Steering unit
ref.: 77 11 160 046
Steering unit mounting
bolt
ref.: 77 03 602 136
Steering unit riser
shims
ref.: 77 11 160 016

2010 Release
E-19
- 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.
 Point E nut: 105Nm.
 Connecting torque rod mounting bolt on yoke: 105Nm.
 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 (see. 4-2 Front axle/Front
load bearing components/Subframe).
3 -
Remove the bar support bearings (2).
4 -
Remove the bar.
5 -
Check the condition of the bearings and replace if
necessary.
- Refitting
Perform the removal steps in reverse order.
Tightening torques:
 Anti-roll bar bearing mounting bolts: 21Nm.
 Anti-roll bar tie-rod mounting nuts: 44Nm.
21

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