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'

-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

4.2.1PRESENTATION 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

4.2.2GEOMETRY 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.

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

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

4.2.4ADJUSTMENT 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.

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