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2015-02-10

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Page Count: 69

USER MANUAL

E. Chassis

2010 Release

E-2

4 CHASSIS

CONTENTS

4 CHASSIS 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'

-0°10'

53kg 53kg -0°10'

6°20' 6°20'

11°15' 317kg 317kg 11°15'

75N/mm

35mm

370kg 370kg 35mm

585mm 2.0 ba

-2°30'

38kg 38kg 0°10'

172kg 172kg -

130N/mm

50mm

210kg 210kg 50mm

1520mm

210mm

Castor angle

Pivot

Spring

Stop

Rear right wheel

Rear left wheel

Camber

Stop

Alignment

(+ opening)

Camber

ressure

when warm

Alignment

(+ opening)

Castor angle

Wheel base

Pivot

Spring

Front right wheel

Castor angle

Pivot

Stop

Body height at front

Front anti-roll bar

Unsprung mass

Front track

Camber

Front left wheel

Alignment

(

+ o

enin

Alignment

(+ opening)

Spring

Castor an

Pivot

Rear track

Body height at rear

Rear anti-roll bar

otal mass

Sprung mass

Unsprung mass

otal mass

Sprung mass

CLIO CUP 2009 BASIC SETTINGS

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-

holde

QQ’ tie-rod

Point P

Anti-roll bar

bearing

Point P

’

Point F:

Upper shock absorber

mountin

Point H

Hub

Point A

Point B

y-axis

Anti-roll bar

2010 Release

E-5

Point E

EE’ support

Anti-roll

bar tie-rod

Support

strut

Pivot

Damper system

axis

y-axis

Point E’ bolt

Pivot holde

Calipe

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

100

150

200

0.05

0.1

0.15

0.2

Speed

[

m/s

]

Force

[

daN

]

---- : Tolerance

: Nominal

2010 Release

E-7

4.2.2 GEOMETRY 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.

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

4.2.3 GEOMETRY VARIATIONS

Roll center height variation

-80

-60

-40

-20

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

0,05

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

4.2.4 ADJUSTMENT 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.

2010 Release

E-11

4.2.5 FRONT 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.

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.

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.

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 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

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.

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

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.

2 1

2010 Release

E-20

4.2.6 WHEEL PASSAGES

The wheel passages are in 2 parts, a rear one and a front one.

Cut out the rear wheel passages like

on the photograph

Fit the wheel passages

2010 Release

E-21

Perform the assembly steps in reverse order to remove it.

Fix the plastic mounting clamps (right

side on photograph)

Tight this 3 screws

behind the wheel

under the protective moulding

Fix a plastic collar between the front

wheel passage and the plastic plate

for engine protection

2010 Release

E-22

4.3 REAR AXLE

4.3.1 PRESENTATION AND CHARACTERISTICS

The rear axle has combined swingshafts.

Calipe

Axle

Shock absorber

mountin

bolt

Hub carrier

Disc

Bearing

mounting bolt on

Bearing

Mounting bolt

on rear axle

(point A)

2010 Release

E-23

Hinges

 Lower: by ball joint.

 Upper (shock absorber): by ball joint.

Suspension

 Suspension spring: 130N.

 Bump stop:

• length: 50mm

• diameter: 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.

Effect of shock absorber movement speed on stress

200

150

100

00.0

5 0.

0.1

Speed [m/s]

Force

[daN]

---- :

Tolerance

Nominal

2010 Release

E-24

4.3.2 GEOMETRY VARIATIONS

Roll center height variation

114

115

116

117

118

119

120

121

122

-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

Roll center height (mm)

ReboundCompression

Per-wheel camber variation

-2,08

-2,06

-2,04

-2,02

-2

-1,98

-1,96

-1,94

-1,92

-1,9

-60-50-40-30-20-100 102030405060708090

Suspension travel (mm)

0 mm for 110 mm body height

Camber (°)

ReboundCompression

Per-wheel alignment variation

-0,7

-0,6

-0,5

-0,4

-0,3

-0,2

-0,1

-55 -45 -35 -25 -15 -5 5 15 25 35 45 55 65 75 85

Suspension travel (mm)

0mm for 110 mm body height

Alignment (°)

ReboundCompression

2010 Release

E-25

4.3.3 ADJUSTMENT OF GEOMETRY

Body height

Body height is adjusted using the nut (1)

mounted on the extension (2).

Loosen the locknut (3).

Adjust body height by tightening or

loosening the nut.

Once the required height has been reached,

tighten the locknut.

Alignment and camber

The alignment and camber of the rear axle are

adjusted by inserting shims (1) between the

hub carrier and the axle.

Depending on the required effect, the shims

should be positioned according to the thickest

edge.

The correspondence between the shims and their resulting alignment/camber is given

in the following table.

Camber shim Alignment shim

shim

10'

77 11 160

176

20'

77 11 160

175

30'

77 11 160

174

1°

77 11 160

173

10'

77 11 160

172

20'

77 11 160

171

30'

77 11 160

170

1°

77 11 160

169

Camber -1,23 -0,1 -0,19 -0,29 -0,98 -0,03 -0,05 -0,08 -0,17

Alignment 0,21 0,03 0,05 0,09 0,16 -0,1 -0,19 -0,28 -0,84

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.

2010 Release

E-26

4.3.4 REAR LOAD-BEARING COMPONENTS

Hub

See 4-5 Brake System/Rear brakes/Hub disc.

Damper system

- Removal

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.

- Refitting

Perform the removal steps in reverse order.

Tightening torques:

 Lower mounting bolt: 105Nm.

 Upper mounting bolt: 80Nm.

2010 Release

E-27

- Disassembly & reassembly

The disassembly & reassembly of the

damper system is performed in the same

manner as for the front axle (see 4-3

Front axle/Front load bearing

components/Support strut).

Rear axle

- Removal

Operations Photos

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 mounting bolts (2).

 The rear axle.

- Refitting

Perform the removal steps in reverse order.

Tightening torques:

 Lower shock absorber mounting bolt: 105Nm.

 Bearing mounting bolt on body: 62Nm.

 Brake hose on caliper: 14Nm.

Drain the braking circuit.

2010 Release

E-28

- Disassembly

Operations Photo

1 - Remove the point A bolt (1) and collect 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): long spacer (Ref 77 11 160 125) inside

and short spacer (Ref: 77 11 160 124) outside.

2010 Release

E-29

4.4 STEERING

4.4.1 STEERING UNIT

Axial ball joint

Specialist tools

 Dir. 1305-01 Axial ball joint removal-refitting tool.

 Dir. 1741 Steering unit bar retainer tool.

 TAV 476 Ball joint puller.

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.

Steering tie-rod ball

joint

Power steering

module

Folding yoke

Intermediate

shaft

Steering

column

Steering unit

Bellows

Steering tie-

rod

2010 Release

E-30

- Removal

Operations Photos

1 -

Place the vehicle on an auto-lift.

2 -

Remove the front wheel on the relevant

side.

3 -

Loosen the alignment locknut (1).

4 -

Remove the point H nut (2).

5 -

Extract the ball joint from point H using

the tool: (1) Tav. 476.

6 -

Remove the 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.

Extract the bellows (3).

Unlock the steering column.

Position the tool: (1) Dir. 1741 on the

steering bar, pinion side.

Release the axial ball joint using the (2)

Dir 1305-01 tool.

14 - Remove the axial ball joint and steering

unit shim (1) (Ref 77 11 160 142).

- Refitting

2010 Release

E-31

Minimum thread installation: 1.5 times the thread diameter, i.e. 18mm of

thread engaged in the ball joint sleeve.

Perform the removal steps in reverse order.

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).

Left ball joint unit Right ball joint unit

Tightening torques:

 Axial ball joint on bar: 80Nm.

 Point H nut: 37Nm.

 Steering tie-rod locknut: 53Nm.

Steering unit

- Removal

Operations Photos

1 -

Remove the subframe (see 4-2 Front

axle/Front load bearing components/

Subframe).

2 -

Remove the two steering unit

mounting bolts (1).

3 -

Remove the steering unit and collect

the unit’s riser shims (2).

2 1

2010 Release

E-32

- Refitting

Operations

1 -

Position the riser shims on the subframe (ref 77 11 160 016, thickness: 5mm).

2 -

Fit the steering unit on the subframe.

3 -

Tighten the two bolts to 105Nm.

4 -

Refit the subframe (see 4-4 Front axle/Front load bearing components/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 the axial ball joint in order to avoid damaging the bellows during

assembly.

2 -

Coat the bellows’ contact surface with the axial ball joint with grease to prevent the

bellows from twisting.

3 -

Attach the bellows with a new clamp (provided with the bellows).

2010 Release

E-33

4.4.2 INTERMEDIATE SHAFT

- Removal

Operations Photos

1 -

Remove the folding yoke bell (1) (discard).

2 -

Set the wheels straight.

3 -

Remove the folding yoke bolt (7) (discard).

4 -

Remove the folding yoke nut (discard).

5 -

Remove the intermediate shaft bolt (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.

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.

2010 Release

E-34

4.4.3 STEERING COLUMN

- Removal

Operations Photo

1 - Set the vehicle wheels straight.

2 - Disconnect the battery's ground cable.

3 - Remove the dashboard.

4 - Disconnect the power steering wiring harness.

5 - Remove the steering wheel, followed by the wheel

hub, after marking their initial positions.

6 - Extract the 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 jet attachment lug (4).

11 - Remove the 4 steering column bolts (5) on the

roll cage crossmember.

12 - Remove the column, power steering module and

intermediate shaft assembly.

It is important not to turn the wheel when

the column has been removed in order to

not offset the position sensor (see 4-4

Steering/EPS unit).

2010 Release

E-35

- Refitting

1 - Refit the steering column.

2 - Tighten the four bolts to 105Nm.

3 - Fit the folding yoke.

4 - Tighten the cam nut to 24Nm.

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 mounting bolt to 44Nm.

9 - Fix the wheel on the hub.

10 - Connect the power steering module wiring harness.

11 - Refit the dashboard and central console.

2010 Release

E-36

4.4.4 ELECTRIC POWER SYSTEM

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

 The condition of all of the EPS mechanical components and electrical

connections should be checked after each race.

 A period of at least 20 seconds should be left between general vehicle

power cut-off and EPS disconnection to allow all internal diagnostic

procedures to complete.

 The unit can reach temperatures of 85°C following repeated operations. It

is therefore 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 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.

2010 Release

E-37

- 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.

2010 Release

E-38

- Removal

Operations Photo

1 -

Remove the steering column (see previous

paragraph).

2 -

Remove the 4 unit mounting bolts (1) on the

steering column.

3 -

Remove the power steering 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).

- Refitting

Operations

Refit the power steering module on the column, using the 4 spacers (ref 77

11 160 149).

Tighten the 4 bolts (1) to 6Nm.

Refit the column (see 4-4 Steering/Steering column).

2010 Release

E-39

4.5 BRAKING SYSTEM

4.5.1 CHARACTERISTICS

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’’

Front brake pads

 Ferodo DS 1.11

Rear brake pads

 Ferodo DS 2500

2010 Release

E-40

Clio Cup is only officially approved by Renault Sport when fitted with Ferodo

brake pads.

Running in

Ferodo DS 1.11 brake pads do not require any specific running-in.

DS 2500 brake pad run-in protocol:

 Clean the brake disc with Emery paper (surface in contact with the pad).

 Remove all traces of previous friction.

 Create a 45° chamfer on the outer circumference 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 100kph).

 Allow to cool (+/- 800meters).

 Repeat the process two or three times.

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.

2010 Release

E-41

4.5.2 FRONT BRAKES

Brake pads

- Removal

Operations Photos

1 -

Push back 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

refitting, where appropriate.

- Refitting

Perform the removal steps in reverse order.

2010 Release

E-42

Maximum authorized contact surface with the disc

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

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 two caliper mounting bolts (2).

4 -

Remove the caliper.

- 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.

5 -

Drain the braking circuit.

2010 Release

E-43

Disk

- Removal

Operations Photos

1 -

Push back the pistons.

Watch out for rising brake fluid levels in the

tank.

2 -

Remove the two bolts (2) holding the caliper on the

pivot.

3 -

Release the caliper and attach 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 11 160 154).

3 -

Fix the assembly with two new bolts and tighten to 21Nm.

4 -

Refit the brake caliper and tighten to 164Nm.

5 -

Press the brake pedal several times in order to place the piston in contact with the

pads.

2010 Release

E-44

4.5.3 REAR BRAKES

Brake pads

Specialist tools:

 Fre 1190-01 Brake caliper piston driver.

- Removal

Operations Photos

1 -

Remove the wheels.

2 -

Remove the lower small column 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 bore using the Fre

1190-01 tool.

4 -

Fit the pads.

5 -

Swivel the caliper downwards into its initial

position.

6 -

Refit a NEW small column bolt.

7 -

Tighten the small column bolt to 32Nm.

2010 Release

E-45

Maximum authorized contact surface with the disc

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

1 -

Remove the wheel.

2 -

Remove the brake hose (2).

Allow for fluid discharge.

3 -

Remove the small column mounting bolts (3) while

holding the nuts (4).

4 -

Remove the caliper.

2010 Release

E-46

- Refitting

Operations

1 - Check the condition of the caliper piston bellows.

2 - Clean the caliper support and the caliper.

3 - Refit the brake pads (see 4-5 Braking system/Rear brakes/Pads).

4 - Refit the caliper.

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 the wheel.

3 -

Remove the brake pads (see previous paragraph).

4 -

Remove the two brake caliper mounting bolts.

5 -

Remove the brake caliper and attach it in the wheel

arch.

6 -

Remove the spindle nut.

7 -

Remove the hub disc (2).

1 2

2010 Release

E-47

- Refitting

Operations

1 -

Fit the hub. disc (1) on the spindle.

2 -

Position the spindle bolt.

3 -

Refit the brake caliper and 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 order to place the piston in contact with the

pads.

- Checking play

Check axial play using a dial gauge mounted on the disc: max. 0.03 mm.

2010 Release

E-48

4.5.4 BRAKING CIRCUIT

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.

- Approved brake fluids

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.

Recommended brake fluid: RENAULT ref. 77 01 422 979 (0.5L bottle).

- 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.

2010 Release

E-49

Master cylinder

- Removal

Operations Photos

1 -

Remove the air box (1) and intake

pipe (2).

2 -

Drain the master cylinder tank with a

syringe.

3 -

Remove the clutch master cylinder

pipe (3).

4 -

Remove the brake pipes, taking care

to catch any brake fluid discharge.

5 -

Remove the 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 the removal steps in reverse order.

The master cylinder seals (9) must be

replaced.

Ensure that the cup is centered on the braking

amplifier when refitting.

Tightening torques:

 Master cylinder tank mounting

bolts: 8.5Nm.

 Master cylinder mounting

nuts: 25Nm.

 Brake pipes: 17Nm.

2010 Release

E-50

Braking amplifier

The brake booster cannot be repaired. Maintenance operations are only allowed on the

following parts:

 Air filter

 Check valve

- Removal

Operations Photos

1 -

Remove the air 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 thrust rod and the

brake pedal.

5 -

Remove the braking amplifier mounting nuts (9)

6 -

Remove the braking amplifier.

7 -

Remove the braking amplifier spacer mounting

bolts (10).

8 -

Remove the braking amplifier spacer.

2010 Release

E-51

- Refitting

Perform the removal steps in reverse order.

Tighten the amplifier and spacer bolts to

21Nm.

Check the dimension L = 171mm, adjustable

using the rod (C).

Drain the braking circuit.

Ensure that the braking amplifier gasket seal

(11) is present and replace it if faulty.

On each removal, systematically replace 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 brake booster.

2 -

Pull and rotate the valve to release it from the rubber

sealing washer.

- Refitting

Perform the removal steps in reverse order.

Check the condition of the sealing washer and check valve and replace them if necessary.

Take care not to push the sealing washer into the braking amplifier when inserting

the valve.

2010 Release

E-52

Wastegate

- Operation

The wastegatecan be adjusted by the driver from his seat:

Tighten the star wheel to increase rear braking,

Loosen the star wheel to reduce rear braking.

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.

- Wastegate operating curve:

Note: The front/rear pressure

distribution can be

displayed on the "Brakes"

page of the display (if the

optional data acquisition

kit 77 11 160 189 has

been fitted onto the

vehicle).

Force applied to pedal

Pressure

(bar)

Rear pressure

fully open

Rear pressure

fully closed

Front pressure

2010 Release

E-53

Removal

Operations Photos

1 - Unscrew the connectors (1) (allow for brake fluid

discharge).

2 - Remove the mounting bolts (2) and the wastegate.

- Refitting

Operations 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 -

Tighten the connectors to 13Nm.

4 -

Drain the braking circuit.

5 -

Preset the wastegate to the centre position: 15 “clicks"

from one of the 2 end positions.

Input

Output

2010 Release

E-54

4.6 WHEELS AND TYRES

4.6.1 CHARACTERISTICS

Wheels

Material: Aluminum/magnesium alloy.

A B C D E

Wheel type Width

(inches)

Wheel rim

profile

Nominal 

under tyre

bead

(inches)

Number of

holes ET offset

8J×17 8 J 17 5 68

Maximum offset: 0.3mm measured on the wheel rim.

Maximum out-of-round: 0.3mm measured on the tyre bead bearing surface.

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

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 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.

4.7 1

2010 Release

E-55

KIT EVO 2009

4.7.1 NOMENCLATURE

WISHBONES

Designation Reference Qty

Assembled wishbone with A and B casings 77 11 162 592 2

External snap ring Ø58 77 11 162 563 2

Point A spacer 77 11 162 525 4

Point B spacer 77 11 162 526 4

Ball joint Ø15 77 11 128 370 4

Internal snap ring Ø30 77 11 128 850 4

M12 deported locknut 77 03 034 248 4

M12 washer 77 11 156 931 4

CHC screw M12 x 145 77 11 162 527 2

CHC screw M12 x 86 77 11 156 908 2

BODYWORK

Black rear diffuser 77 11 162 532 1

Diffuser’s duct 77 11 162 533 2

External exhaust nozzle 77 11 162 534 2

Front bumper skin 77 11 162 535 1

Front bumper inferior plastic fence 77 11 162 536 1

Inferior deflector 77 11 162 537 1

Left aerodynamic blade 77 11 162 538 1

Right aerodynamic blade 77 11 162 539 1

Anti-fog light left cover 77 11 162 540 1

Anti-fog light right cover 77 11 162 541 1

Front left bumper support 77 11 162 542 1

Front right bumper 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 11 162 547 1

Black left rearview mirror shell 77 11 162 548 1

Black right rearview mirror shell 77 11 162 549 1

Left external rearview mirror 77 11 162 550 1

Right external rearview mirror 77 11 162 551 1

Assembled Renault ensign 77 11 162 565 1

FASTENERS

Diffuser screw 77 03 017 090 2

Diffuser nut 77 03 034 276 2

Screw for diffuser’s duct 77 03 008 211 6

Nut for diffuser’s duct 77 03 046 151 6

F1 blade fitting screw 77 03 017 101 8

Screw for bumper fitting on inferior radiator support 77 03 602 206 2

Screw for bumper fitting on front quarter panel 77 03 019 211 2

Retainer for bumper fitting on superior radiator support

77 03 072 360 2

Bumper retainer 82 00 700 969 2

Star rivet 77 03 072 419 18

Plastic clip for headlight fitting on front quarter panel 77 03 081 222 2

Black star rivet for superior bumper trim cover 77 03 072 322 4

Plastic clip for superior bumper trim cover 77 03 072 361 2

2010 Release

E-56

4.7.2 NEW WISHBONE MOUNTING

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 :

Point A bolt:

Screw : 77 11 162 527

Under head washer : 77 11 156 931

Locknut : 77 03 034 115

Tightening torque : 80 N.m

Point B bolt :

Screw : 77 11 156 908

Under head washer : 77 11 156 931

Locknut : 77 03 034 115

Tightening torque : 80 N.m

2010 Release

E-57

4.7.3 EXTERNAL MIRRORS

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.

4.7.4 DIFFUSER

- Fit the external nozzles 77 11 162 534 on the 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)

2010 Release

E-58

- Cut right the exit of the silencer tubes starting from the bottom of the genuine

bevel :

Recovering distance in the duct

between 20 and 30 mm

- 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) :

4.7.5 FRONT HEADLIGHTS

The front headlights directly take place instead of the old ones.

- Change the plastic nut 77 03 081 222 on each side :

2010 Release

E-59

- Fit the bumper supports on the headlights using 4 rivets 77 03 072 419 (2 per

headlight):

- Use the fasteners of the old ones (2 x 3 screws).

- Connect the headlight to the front wiring loom.

! The connector of the left headlight is reversed compared to the old one!

4.7.6 FRONT BUMPER

- Get back the 3 fences of the old bumper.

- Fit the towing hook.

- Fit the Renault ensign using the 2 screws of the old ensign :

- Fit the plastic central fence 77 11 162 536 on the bumper.

- Fit the superior bumper trim cover on the bumper.

2010 Release

E-60

- 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 :

Rivets 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 the new aerodynamic blade (in 2 parts) on the bumper and fasten it definitely

using 4 rivets 77 03 072 419 :

- Bend the 2 brackets of the inferior deflector:

2010 Release

E-61

- Fit the deflector using the 10 rivets 77 03 072 419 :

- Fit the old central fence using 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 on the bumper.

- Fit the bumper on the car. Fasteners are the same as the ones used for the old

one.

2010 Release

E-62

- Cut the inferior part of the towing hook plastic trap door:

- Fit 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 standard rivet with a dished washer, in case you would not

have any star rivet:

2010 Release

E-63

4.8 TIGHTENING TORQUES

Parts Tightening

torques in Nm Specific

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 yoke 105

Connecting torque rod mounting bolt on

subframe 105

Bolts for points P and P’ 120

QQ’ tie-rod mounting bolts to body 105

QQ’ tie-rod mounting bolts to subframe 80

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

2010 Release

E-65

Electric power steering

Module mounting bolt on steering column 6

BRAKING SYSTEM

Front brake caliper

Brake caliper mounting bolt on pivot 164

Brake hose 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 brake booster 23

M10 x 100 master cylinder outlets 13

Braking amplifier

Mounting bolt on bulkhead 21

Spacer mounting bolt 21

Rear brake limiter

Lines on brake limiter 13

2010 Release

E-66

Parts Tightening

torque in Nm Specific

recommendations

(1) Point A bolt 80

(2) Point B bolt 80

(3) EE’ support nut on wishbone

(point E) 105 Bolt class: 12.9

(4) EE’ support bolt on pivot holder 105

(5) EE’ support bolts on pivot (point

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

bolt on pivot holder 100

(11) Anti-rotation tie-rod mounting

bolt on wishbone 100

(12) Point H ball joint nut 37

(13) Anti-roll bar tie-rod mounting bolt

on support strut 44

(14) Wheel bearing mounting bolt 105

14 8

2010 Release

E-67

Parts Tightening

torque in Nm Specific

recommendations

(14) Anti-roll bar mounting bolt 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 mounting bolt

on body (point P’) 120

(20) Rear subframe mounting bolt on

body (point P) 120

2010 Release

E-68

Parts Tightening

torque in Nm Specific

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 bearing mounting bolt on

rear axle 125

2010 Release

E-69

Parts Tightening

torque 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 mounting bolt

on column 34

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