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Clio Cup
2009
PRESENTATION
2009 Release
1 PRESENTATION
1 PRESENTATION 1
1.1 IDENTIFICATION 2
1.1.1 ROLL CAGE 2
1.1.2 CHASSIS NUMBER 2
1.1.3 HOLOGRAMS 3
1.1.4 MARKINGS 3
1.2 DIMENSIONS 4
1.3 CAPACITIES 5
1.4 GENERAL CHARACTERISTICS 6
1.5 HANDLING 7
1.5.1 LIFTING AT FRONT 7
1.5.2 LIFTING AT REAR 7
1.5.3 TOWING AT FRONT 7
1.5.4 TOWING AT REAR 7
1.6 USING THE CAR 8
1.6.1 CONTROL PANEL 8
1.6.2 DISPLAY 9
1.6.3 BASIC PROCEDURES 13
1.6.4 ADJUSTING THE DRIVING POSITION 16
1.6.5 VENTILATION 16
1.6.6 FUEL LEVEL 17
1.7 SAFETY EQUIPMENT 18
1.7.1 EXTINGUISHER 18
1.7.2 CIRCUIT-BREAKER 20
1.7.3 OTHER SAFETY EQUIPMENT 21
1.7.4 PASSENGER SEAT 21
1.8 BALLAST 22
1.9 APPENDICES 23
1.9.1 LIST OF MARKED PARTS 23
1.9.2 RECOMMENDATIONS REGARDING REPLACEMENT OF MECHANICAL
COMPONENTS 25
1.9.3 LIST OF ALARMS 27
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Clio Cup
2009
ENGINE
2009 Release
2 ENGINE
''
2 ENGINE 1
2.1 ENGINE 2
2.1.1 ENGINE IDENTIFICATION 2
2.1.2 LUBRICATION 3
2.1.3 SEALED PARTS 4
2.1.4 REMOVAL & REFITTING OF THE POWERTRAIN 5
2.2 FUEL MIXTURE 12
2.2.1 PRESENTATION 12
2.2.2 OPERATING PRINCIPLE 17
2.3 STATIC IGNITION 19
2.3.1 DESCRIPTION 19
2.4 POWER SUPPLY 20
2.4.1 DESCRIPTION 20
2.5 TIGHTENING TORQUES 21
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Clio Cup
2009
TRANSMISSION
2009 Release
3 TRANSMISSION
''
3 TRANSMISSION 1
3.1 CLUTCH 2
3.1.1 PRESENTATION 2
3.1.2 ASSEMBLY & DISASSEMBLY 3
3.2 GEARBOX 7
3.2.1 PRESENTATION AND CHARACTERISTICS 7
3.2.2 ASSEMBLY & DISASSEMBLY 9
3.2.3 BARREL POTENTIOMETER ADJUSTMENT 27
3.2.4 ENGINE CUT-OFF CONTACTOR ADJUSTMENT 28
3.3 GEARSHIFT 29
3.3.1 USE 29
3.3.2 GEARSHIFT LEVER 30
3.3.3 CONTROL ROD 31
3.3.4 UNLOCKING CABLE 32
3.4 TRANSMISSION 34
3.4.1 ASSEMBLY & DISASSEMBLY 34
3.5 TIGHTENING TORQUES 37
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- 38 -
Clio Cup
2009
CHASSIS
2009 Release
4 CHASSIS
CONTENTS
4 CHASSIS 1
4.1 SETUP 2
4.2 FRONT AXLE 3
4.2.1 PRESENTATION AND CHARACTERISTICS 3
4.2.2 GEOMETRY INSPECTION 6
4.2.3 GEOMETRY VARIATIONS 8
4.2.4 ADJUSTMENT OF GEOMETRY 9
4.2.5 FRONT LOAD-BEARING COMPONENTS 10
4.2.6 WHEEL PASSAGES 19
4.3 REAR AXLE 21
4.3.1 PRESENTATION AND CHARACTERISTICS 21
4.3.2 GEOMETRY VARIATIONS 23
4.3.3 ADJUSTMENT OF GEOMETRY 24
4.3.4 REAR LOAD-BEARING COMPONENTS 25
4.4 STEERING 28
4.4.1 STEERING UNIT 28
4.4.2 INTERMEDIATE SHAFT 32
4.4.3 STEERING COLUMN 33
4.4.4 ELECTRIC POWER SYSTEM 35
4.5 BRAKING SYSTEM 38
4.5.1 CHARACTERISTICS 38
4.5.2 FRONT BRAKES 39
4.5.3 REAR BRAKES 42
4.5.4 BRAKING CIRCUIT 46
4.6 WHEELS AND TYRES 52
4.6.1 CHARACTERISTICS 52
4.7 KIT EVO 2009 53
4.7.1 NEW WISHBONE MOUNTING 53
4.7.2 EXTERNAL MIRRORS 54
4.7.3 DIFFUSER 54
4.7.4 FRONT HEADLIGHTS 55
4.7.5 FRONT BUMPER 56
4.8 TIGHTENING TORQUES 60
-1-
2009 Release
4.1 SETUP
The following Clio Cup settings apply with a 70kg driver and 40kg of fuel on board.
Front track
1,528mm
Body height at front
110mm
Front anti-roll bar
22mm
Front left wheel Front right wheel
Camber -3°10' Unsprung mass Camber -3°10'
Alignment Alignment
-0°10' 53kg 53kg -0°10'
(+ opening) (+ opening)
Castor angle 6°20' Sprung mass Castor angle 6°20'
Pivot 11°15' 317kg 317kg Pivot 11°15'
Spring 75N/mm Total mass Spring 75N/mm
Stop 35mm 370kg 370kg Stop 35mm
-2-
2009 Release
Anti-rotation tie-
rod QQ’ tie-rod
Point A
Hub
Anti-roll bar
Point F’:
Pivot/pivot-
holder
Point H
Point B
Point F:
Upper shock absorber
mounting Point P
x-axis
Anti-roll bar
Point P’
bearing
y-axis
-3-
2009 Release
Damper system
z-axis
y-axis
Support Anti-roll
strut bar tie-rod
Pivot
Pivot holder
Point E’ bolt
Disk
-4-
2009 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,
• 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.
200
150
100
: Nominal
50
---- : Tolerance
Force 0
0 0.05 0.1 0.15 0.2
[daN]
-50
-100
-150
-200
Speed
[m/s]
-5-
2009 Release
- Conditions
The front body height is measured at the level of the lower front wishbone mounting (1).
Ground projection
- Measuring the rear body height under subframe
The rear body height is measured at the level of the rear axle point A bolt.
-6-
2009 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
• Bearing clearance
-7-
2009 Release
140
120
100
Roll center height (mm)
80
60
40
20
C ompression Rebound
0
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
-20
-40
-60
-80
Suspension travel (mm)
0mm for 110 mm body height
-3,15
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
-3,2
-3,25
-3,3
Camber (°)
-3,35
C ompression Rebound
-3,4
-3,45
-3,5
-3,55
-3,6
-3,65
Suspension travel (mm)
0mm for 110 mm body height
0,1
0,05
C ompression Rebound
0
Alignment (°)
-0,1
-0,15
-0,2
-0,25
Suspension travel (mm)
0mm for 110 mm body height
-8-
2009 Release
Body height
Wheel alignment
Camber
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.
-9-
2009 Release
Support strut
- Removal
Photos
Operations
- 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.
- 10 -
2009 Release
- Disassembly
Operations Photos
- Reassembly
Operations
1 - Thoroughly clean the inside of the support strut and shock absorber cartridge.
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).
- 11 -
2009 Release
Pivot holder
- Removal
Operations Photos
- Refitting
- 12 -
2009 Release
EE’ support
- Removal
Operations Photos
- Refitting
Wishbone
- Removal
Operations Photos
- 13 -
2009 Release
- Refitting
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.
Front of vehicle
In case of replacement, the new part must In case of replacement, the new part must be
be fitted in the same position: the shoulder fitted in the same position: the shoulder area
area of the A casing must rest on the of the B casing must rest on the wishbone
wishbone machined surface (1). machined surface in order to permit the
fitting of the snap ring (1).
- 14 -
2009 Release
Subframe
- Removal
Operation Photos
- 15 -
2009 Release
9
Extract the subframe by lowering the
12 -
hydraulic plate.
10
Do not forget the subframe braces and steering unit riser shims.
Aluminum
reinforcement plate
ref. 77 11 160 151
Spacer:
ref 77 11 160 184
Bolt ref.:
77 11,156,911
+ washer
- 16 -
2009 Release
Steering unit
ref.: 77 11 160 046
- 17 -
2009 Release
- Refitting
Anti-roll bar
- Removal
Operations Photos
1
2-
Remove the subframe (see. 4-2 Front axle/Front 2
load bearing components/Subframe).
- Refitting
- 18 -
2009 Release
The wheel passages are in 2 parts, a rear one and a front one.
- 19 -
2009 Release
- 20 -
2009 Release
Caliper
Disc
Bearing
Hub carrier mounting bolt on
Shock absorber
mounting bolt
Axle
Bearing
Mounting bolt
on rear axle
(point A)
- 21 -
2009 Release
Hinges
Suspension
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.
20
0
15
0
10
0
5 :
Force 0 Nominal
[daN] ---- :
Tolerance
0
0 0.0 0. 0.1 0.
5 1 5 2
-
50
-
100
-
150
-
200
Speed [m/s]
- 22 -
2009 Release
122
121
Roll center height (mm)
120
119
118
117
116
115
C ompression Rebound
114
-55 -45 -35 -25 -15 -5 5 15 25 35 45 55 65 75 85
Suspension travel (mm)
0 mm for 110 mm body height
-1,9
-60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90
-1,92
-1,94
-1,96
Camber (°)
-1,98
C ompression Rebound
-2
-2,02
-2,04
-2,06
-2,08
Suspension travel (mm)
0 mm for 110 mm body height
-0,2
Alignment (°)
-0,3
C ompression Rebound
-0,4
-0,5
-0,6
-0,7
- 23 -
2009 Release
Body height
The correspondence between the shims and their resulting alignment/camber is given in the
following table.
To obtain the recommended setup (see 4-1 Setup) the following shim set should be used:
Alignment (wheel opening): one 1° shim,
Camber (wheel negative camber): one 1° shim.
Note: To achieve the same setting for both rear axle wheels, the shims used on the
left and right-hand sides may differ.
- 24 -
2009 Release
Hub
Damper system
- Removal
Operations Photos
- Refitting
- 25 -
2009 Release
Rear axle
- Removal
Operations Photos
- Refitting
- 26 -
2009 Release
- Disassembly
Operations Photo
1
2 - Remove the snap ring. 3
- Reassembly
Follow spacer assembly direction (2): long spacer (Ref 77 11 160 125) inside and
short spacer (Ref: 77 11 160 124) outside.
- 27 -
2009 Release
4.4 STEERING
Power steering
module
Steering
column Steering tie-rod ball
joint
Intermediate
shaft
Folding yoke
Steering tie-
rod
Steering unit
Bellows
Specialist tools
The axial ball 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 steering unit bar during this operation, it
MUST be supported using the tool: Dir. 1741.
- 28 -
2009 Release
- Removal
Operations Photos
2
Extract the ball joint from point H using
5-
the tool: (1) Tav. 476.
1
Remove the axial ball joint and steering
14 -
unit shim (1) (Ref 77 11 160 142).
- Refitting
- 29 -
2009 Release
Minimum thread installation: 1.5 times the thread diameter, i.e. 18mm of thread
engaged in the ball joint sleeve.
Note: Position the steering unit shim (Ref 77 11 160 142) before fitting the axial
ball joint onto the steering unit.
Fit the bellows (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).
1
2
Tightening torques:
Axial ball joint on bar: 80Nm.
Point H nut: 37Nm.
Steering tie-rod locknut: 53Nm.
Steering unit
- Removal
Operations Photos
- 30 -
2009 Release
- Refitting
Operations
1 - Position the riser shims on the subframe (ref 77 11 160 016, thickness: 5mm).
4 - Refit the subframe (see 4-4 Front axle/Front load bearing components/Subframe).
Bellows
- Bellows assembly
Fit a nose cone on the axial ball joint in order to avoid damaging the bellows during
1-
assembly.
Coat the bellows’ contact surface with the axial ball joint with grease to prevent the
2-
bellows from twisting.
3 - Attach the bellows with a new clamp (provided with the bellows).
- 31 -
2009 Release
- Removal
Operations Photos
- Refitting
Systematically replace the folding yoke bolt (ref 77 03 602 097) and cam nut after
each removal.
Note: On a new intermediate shaft, the folding yoke cam nut is pre-assembled, do not
remove the bell.
Follow the direction of assembly of the folding yoke bolt and cam nut.
Tightening torques:
Folding yoke bolt on steering box: 24Nm.
Bolt on steering column: 32Nm.
- 32 -
2009 Release
- Removal
Operations Photo
- 33 -
2009 Release
- Refitting
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.
- 34 -
2009 Release
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.
Safety recommendation
The EPS system may generate significant forces and rotation speeds, which may in turn cause
injury. It is therefore important to handle it with caution, in accordance with the maintenance
guidelines (see following paragraph) and to return it to the supplier prior to re-use if it has
been damaged.
Maintenance guidelines
Use
- Start-up
Ensure that the EPS is correctly connected to the wiring harness.
Turn on the vehicle's electrics (button (12) on the control panel; see 1-6
Using the car).
After a short period of time, the EPS makes a "clicking" noise. This indicates
that the unit is powered up and ready to use.
Turn the wheel. The EPS should function and the less effort should be required
to turn the wheel.
For the wheel position sensor to transmit its measurements, it must first be
calibrated. The power steering will function correctly, even if the sensor has
not been calibrated, but angle measurements will not be available on data
acquisition.
To calibrate the sensor, turn the wheel slowly to the 0° position (this
information is visible from the “Vision” software see 6 Operating
software/Vision). This position is an item of production data and may not
correspond to the vehicle’s wheels being straight. It is for this reason that,
when calibrating the sensor for the first time, the wheel must be rotated
360°(don’t turn up to the stop!) in each direction. The 0° position will then
correspond to the straight wheels position. The system will maintain this
calibration as long as the vehicle’s electrics are on, but will require re-
calibrating to 0° on each general power cut.
- 35 -
2009 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)).
Fault diagnosis
Symptom 1: When the system is powered up, the effort required to turn the wheel does
not reduce. Furthermore, the system does not “click”.
Solutions:
Ensure that the ignition switch is in the up position (on).
Check that the wiring harness is connected to the battery and that the battery
is charged.
Check all connections between the battery, EPS and ignition switch. Ensure
that there is no power loss and that they are connected to the correct pins.
Check that all fuses between the battery and the EPS are in working 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 stops before reaching
full travel. When the wheel it turned in the opposite direction, however, the power steering
operates correctly to full travel.
Solution: This problem is due to the maximum rotation allowed by the system of 1600°.
If the 0° position stored by the system is significantly different from the angle of the
wheels, the angle measured by the EPS may exceed the maximum value in one direction.
To solve this problem, disconnect the intermediate shaft and rotate the wheel 360° in the
direction of correct system operation. This will align the system’s 0° position with that of
the wheels.
Symptom 3: When driving the vehicle, the power steering varies randomly, even though
the system is constantly powered up.
Solution: Ensure that all connections between the EPS, the battery and the ignition switch
are shielded and sealed and that there is no corrosion or dirt on them.
If these solutions fail to solve the problem, the system must be immediately returned to the
Alpine after-sales service.
- 36 -
2009 Release
- Removal
Operations Photo
- Refitting
Operations
Refit the power steering module on the column, using the 4 spacers (ref 77
1-
11 160 149).
2 - Tighten the 4 bolts (1) to 6Nm.
- 37 -
2009 Release
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.
Minimum disc thickness: 9.5mm.
Master cylinder
Diameter: 23.8mm.
Brake booster
Diameter 10’’
Clio Cup is only officially approved by Renault Sport when fitted with Ferodo brake
pads.
Running in
Under no circumstances during run-in should brake pad temperature exceed 300°C to
400°C.
Brake pad operation at low temperatures may lead to the build-up of friction material
on the disc. This deposit may cause vibrations when braking. Should this occur, buff
the discs to eliminate this phenomenon.
- 38 -
2009 Release
Brake pads
- Removal
Operations Photos
1-
Watch out for rising brake fluid levels in the
tank.
1
3 - Remove the spring and lower spindle (2).
2
- Refitting
- 39 -
2009 Release
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.
- Removal
Operations Photos
- Refitting
Operations
1 - Fit the caliper on the pivot and attach it using its bolts (2).
2 - Tighten to 164Nm.
3 - Check the condition of the hose (replace if necessary) and attach with the banjo bolt.
4 - Tighten to 14Nm.
- 40 -
2009 Release
Disk
- Removal
Operations Photos
1-
Watch out for rising brake fluid levels in the
tank.
1
Remove the two bolts (2) holding the caliper on the
2-
pivot. 2
3
4- Remove the two disc mounting bolts (3).
- Refitting
Operations
Press the brake pedal several times in order to place the piston in contact with the
5-
pads.
- 41 -
2009 Release
Brake pads
Specialist tools:
- Removal
Operations Photos
- Refitting
Operations Photos
Push caliper piston back into its bore using the Fre
3-
1190-01 tool.
- 42 -
2009 Release
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.
- Removal
Operations Photos
- 43 -
2009 Release
- Refitting
Operations
Tightening torques:
7- Small column bolts: 32Nm.
Brake hose: 14Nm.
Hub disc
- Removal
Operations Photos
- 44 -
2009 Release
- Refitting
Operations
Press the brake pedal several times in order to place the piston in contact with the
7-
pads.
- Checking play
Check axial play using a dial gauge mounted on the disc: max. 0.03 mm.
- 45 -
2009 Release
Brake fluid
- Top-up
Brake pad wear leads to a progressive drop in brake fluid levels in the tank. Do not
compensate this drop, the level shall be restored on the next brake pad change.
Ensure, however, that it does not drop below the minimum mark.
The combination of two incompatible brake fluids in the braking circuit may lead to significant
leakage risks caused mainly by damage to gaskets and cups. To avoid such risks, only those
fluids inspected and approved by our laboratories, and compliant with the SAE J 1703 dot 5
standard should be used.
- Bleeding
Drainage should be performed starting with the caliper furthest away from the master cylinder
and ending with the nearest.
Open the brake limiter to the maximum, taking care to note its initial
position.
Bleed the rear right-hand caliper.
Bleed the rear left-hand caliper.
Bleed the outer body of the front right-hand caliper.
Bleed the inner body of the front right-hand caliper.
Bleed the outer body of the front left-hand caliper.
Bleed the inner body of the front left-hand caliper.
Reset the limiter to its initial setting.
The level of brake fluid must never be allowed to drop below the minimum level during
bleeding.
- 46 -
2009 Release
Master cylinder
- Removal
Operations Photos
2
Remove the air box (1) and intake pipe 1
1-
(2).
- Refitting
Tightening torques:
Master cylinder tank mounting
bolts: 8.5Nm.
Master cylinder mounting nuts:
25Nm.
Brake pipes: 17Nm.
- 47 -
2009 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
- 48 -
2009 Release
- Refitting
Check valve
- Removal
Operation Photo
- Refitting
Take care not to push the sealing washer into the braking amplifier when inserting the
valve.
- 49 -
2009 Release
Wastegate
- Operation
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.
60
50
Rear pressure
Pressure fully open
(bar) 40
Rear pressure
30
fully closed
20 Front pressure
10
0
Force applied to pedal
- 50 -
2009 Release
Removal
Operations Photos
- Refitting
Operations Photos
- 51 -
2009 Release
4.6.1 CHARACTERISTICS
Wheels
A B C D E
Nominal ∅
Width Wheel rim Number of
Wheel type under tyre ET offset
(inches) profile holes
bead (inches)
8J×17 8 J 17 5 68
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’ support in steering lock
position.
Tyres
Dry Wet
Front S9B P2E
Type
Rear S9B P2E
Front 20/61-17 20/61-17
Dimensions
Rear 20/61-17 20/61-17
*The cold pressure values are given for information and should be adjusted according to track
conditions (temperature, roughness, grip, amount of water, etc.).
Notes:
To ensure predictable and reproducible pressure increase, we strongly recommend
the use of a water vapor-free inflation gas (dry air, nitrogen, etc.).
To ensure a good valve seal, the cap should always be used.
The wheels are identified by the two engravings on the inside, corresponding to their
widths (see photos). Only the engraving with a cross (1) on the right should be
taken into account.
- 52 -
2009 Release
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)
− Heat the casing (oven) et cool the ball joint (freezer)
Do not heat the complete wishbone more than 100°C not to damage the point E
ball joint.
− Fit the ball joint using a pressing machine leaning on the external ring of the ball
joint, without glue (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 ball joint, you could damage
the parts because of too important force. Be careful to not deform the inner shoulder of the B
casing.
To ease the understanding of the fitting on the car, hereafter is a cut view of a left wishbone
mounted on the subframe :
- 53 -
2009 Release
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.
4.7.3 DIFFUSER
- Fit the ducts 77 11 162 533 using the 6 screws 77 03 008 211 and the 6 nuts 77
03 046 151 :
(Recommended glue : Loctite® 222 low strength threadlock)
- 54 -
2009 Release
- Cut right the exit of the silencer tubes starting from the bottom of the genuine bevel :
- 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 fasteners included) :
The front headlights directly take place instead of the old ones.
- 55 -
2009 Release
- Fit the bumper supports on the headlights using 4 rivets 77 03 072 419 (2 per
headlight):
- 56 -
2009 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 :
- 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 :
- 57 -
2009 Release
- Fit the 2 old anti-fog light fences (glue, plastic collars or star rivets) on the anti-fog
light covers :
- 58 -
2009 Release
- Cut the inferior part of the towing hook plastic trap door:
NOTA : It is possible to use a standard rivet with a dished washer, in case you would not
have any star rivet:
- 59 -
2009 Release
Tightening Specific
Parts
torques in Nm recommendations
FRONT AXLE
Wheels
Wheel studs 100 Copper grease
Wheel nuts 110
Wheel speed sensor 8 to 10
Drivetrain nut 280
Damper system
Upper shock absorber nut 100
Point F plate bolt on body 100
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
Point B bolt 80
Subframe
Aluminum plate mounting bolt on subframe 100
Connecting torque rod mounting bolt on GB
105
yoke
- 60 -
2009 Release
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
- 61 -
2009 Release
BRAKING SYSTEM
- 62 -
2009 Release
6 13 8
14
10
12 4
5 11
1
Tightening Specific
Parts
torque in Nm recommendations
(1) Point A bolt 80
(2) Point B bolt 80
EE’ support nut on wishbone (point
(3) 105 Bolt class: 12.9
E)
(4) EE’ support bolt on pivot holder 105
(5) EE’ support bolts on pivot (point E’) 26.5
Pivot ball joint nut on pivot holder
(6) 140
(point F’)
(7) Support strut bolt on pivot holder 105
(8) Point F plate bolt on body 100
(9) Upper shock absorber nut 105
Anti-rotation tie-rod mounting bolt
(10) 100
on pivot holder
Anti-rotation tie-rod mounting bolt
(11) 100
on wishbone
(12) Point H ball joint nut 37
Anti-roll bar tie-rod mounting bolt on
(13) 44
support strut
(14) Wheel bearing mounting bolt 105
- 63 -
2009 Release
14
15
19 20
16
18
17
Tightening Specific
Parts
torque in Nm recommendations
(14) Anti-roll bar mounting bolt on tie-rod 44
Anti-roll bar bearing bolts on
(15) 21
subframe
Steering unit mounting bolt on
(16) 24
subframe
(17) QQ’ tie-rod bolt on subframe 80
(18) QQ’ tie-rod bolt on body 105
Reinforcement plate mounting bolt on
(19) 120
body (point P’)
Rear subframe mounting bolt on
(20) 120
body (point P)
- 64 -
2009 Release
4
5
Tightening Specific
Parts
torque in Nm recommendations
- 65 -
2009 Release
2
3
Tightening Specific
Parts
torque in Nm recommendations
(1) Folding yoke cam bolt 24
Column mounting bolt on roll cage
(2) 105
crossmember
(3) Sheath bolt 21
Sheath mounting bolt on roll cage
(4) 21
stays
Intermediate shaft mounting bolt on
(5) 34
column
- 66 -
Clio Cup
2009
WIRING AND ELECTRICAL
EQUIPMENT
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