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