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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
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2 ENGINE






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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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- 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.

CLIO CUP 2009 BASIC SETTINGS

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

Wheel base 2,585mm Tyre pressure 2.0 bar

when warm

Rear left wheel Rear right wheel

Camber -2°30' Camber -2°30'
Unsprung mass
Alignment Alignment
38kg 38kg 0°10'
(+ opening) (+ opening)
Castor angle - Sprung mass Castor angle -
Pivot - 172kg 172kg Pivot -
Spring 130N/mm Total mass Spring 130N/mm
Stop 50mm 210kg 210kg Stop 50mm
Rear track
1520mm
Body height at rear
210mm
Rear anti-roll bar
-

-2-
 2009 Release

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 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

EE’ support Point E

Point F’: Roller bearing

Pivot to pivot
holder mounting
ball joint
Hub
Caliper

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.

Effect of shock absorber movement speed on stress

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

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 Front Rear
tyres. body body
 Tyre pressure at 2 bars. height height

- Measuring the front body height

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

 Wheel run-out (max. 0.3mm)

 Body and cup height symmetry

- Front axle diagnostics

Incident Possible cause(s)

- Distorted wishbone
Faulty castor angle
- Distorted side member or subframe-axle

Camber + pivot correct overall, but:

- Individual faulty camber
- Individual pivot wrong.
Camber correct, but faulty pivot
Pivot correct, but faulty camber
Faulty variation in wheel alignment
Wheel alignment off by more than 6mm
- Distorted wishbone
- Distorted side member or subframe-axle
- Distorted pivot
- Distorted pivot
- Steering unit mounting on subframe
- Distorted left or right-hand hub carrier

-7-
2009 Release

4.2.3 GEOMETRY VARIATIONS

Roll center height variation

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

Per-wheel camber variation

-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

Per-wheel alignment variation

0,1

0,05
C ompression Rebound
0
Alignment (°)

-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35

-0,05

-0,1

-0,15

-0,2

-0,25
Suspension travel (mm)
0mm for 110 mm body height

-8-
2009 Release

4.2.4 ADJUSTMENT OF GEOMETRY

Body height

Body height is adjusted using the nut (1) 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, 2
tighten the locknut.

Wheel alignment

Adjust the clip by means of the steering tie- 1

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).
1
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.

-9-
2009 Release

4.2.5 FRONT LOAD-BEARING COMPONENTS

Support strut

- Removal

Photos
Operations

1 - Remove the wheel.

Remove the upper mounting nut (2) of the anti-roll 2

2-
bar tie-rod.
1

Remove the support strut mounting bolt (1) on the

3-
pivot holder.

4 - Extract the pivot-holder support strut.

Attach the pivot holder in the wheel arch to avoid 3

5-
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.

- 10 -
2009 Release

- Disassembly

Operations Photos

Remove the upper nut, holding the shock 1

1-
absorber with a hexagonal socket wrench.

2 - Remove the snap ring (1).

Loosen the nut (5) and locknut (6) so that

3-
the spring is relaxed (3).
2
Remove the retainer ring (2) from the
4- 3
spring cup.

5 - Remove the suspension spring cup (3).

4

6 - Remove the suspension spring (4).

5
Unscrew the support strut shock absorber
7-
rod 6

- 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.

- 11 -
2009 Release

Pivot holder

- Removal

Operations Photos

1- Remove the wheel.

2

Remove the brake caliper (see 4-5 Brake

2- system/Front brakes/Calipers) and attach it in
the wheel arch.

3- Remove the point E nut (1).

3
Extractsupport EE' from the point E ball joint; a
4-
ball joint puller must be used to do this.

Remove the anti-roll bar mounting nut from the

5-
pivot holder(3). 1

Disconnect the steering rod at the level of point

6-
H (4).

Remove the wheel speed sensor at the level of

7-
the pivot.

Remove the support strut mounting bolt (2)

8-
on the pivot holder.

9- Extract the pivot-holder support strut.

Remove the pivot-holder, pivot and EE’ support

10 - 4
assembly.

11 - Remove the EE’ support (see following section)

12 - Remove the nut from point F’.

Remove the pivot from the pivot holder using a

13 -
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.

- 12 -
2009 Release

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;

3-
a ball joint puller must be used to do this. 2
4 - Remove the point E’ ball joint mounting bolt (2).
1
Remove the 3 EE’ support mounting bolts on the
5-
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

Remove the attachment (1) of the anti-roll bar 3

1-
at the level of the wishbone.

2 - Remove the point E nut (2).

Extract support EE' from the point E ball joint;

3-
a ball joint puller must be used to do this.

Remove the two wishbone mounting bolts (3)

4-
on the subframe.
1
2
5 - Remove the wishbone.

- 13 -
2009 Release

- 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

Front of vehicle

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).

- 14 -
2009 Release

Subframe

- Removal

Operation Photos

Remove the intermediate shaft (see 4-4 Steering/Intermediate shaft).

1-
Note: Do not turn the wheel when the shaft is not connected to the steering unit.

2 - Remove the connecting torque rod.

Place a hydraulic plate in contact under the 2

3-
subframe.

Remove the wheel speed sensors (2) at the

4 - level of the pivots and disconnect them from
the support (3) on the steering tie-rod.

5 - Remove the point E nuts (4).

Extract the EE' support from the point E ball 4

6 - joint; a ball joint puller must be used to do
this.

- 15 -
 2009 Release

Disconnect the anti-rotation tie-rods at the 5 8

7-
level of the wishbones (5).
7
Disconnect the steering tie-rods at the level
8-
of points H (6).

Disconnect the anti-roll bar tie-rods at the

9-
level of the support struts (7).

Disconnect the QQ’ tie-rods at the body level

10 -
(8).
6

Remove the bolts from points P (9) and P’

11 -
(10).

9
Extract the subframe by lowering the
12 -
hydraulic plate.
10

- Preparing the subframe before refitting

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 mounting

bolt
ref.: 77 03 602 136

Steering unit
ref.: 77 11 160 046

Steering unit riser

shims
ref.: 77 11 160 016
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

- 17 -
2009 Release

- 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

Remove the anti-roll bar tie-rod mounting nuts

1-
(1) at the level of the anti-roll bar.

1
2-
Remove the subframe (see. 4-2 Front axle/Front 2
load bearing components/Subframe).

3 - Remove the bar support bearings (2).

4 - Remove the bar.

Check the condition of the bearings and replace if

5-
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.

- 18 -
2009 Release

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

1 on the photograph

2 Fit the wheel passages

- 19 -
2009 Release

3 Fix the plastic mounting clamps (right

side on photograph)

4 Tight this 3 screws

behind the wheel under the protective moulding

Fix a plastic collar between the front

5 wheel passage and the plastic plate
for engine protection

Perform the assembly steps in reverse order to remove it.

- 20 -
 2009 Release

4.3 REAR AXLE

4.3.1 PRESENTATION AND CHARACTERISTICS

The rear axle has combined swingshafts.

Caliper

Disc

Bearing
Hub carrier mounting bolt on

Shock absorber
mounting bolt

Axle

Bearing
Mounting bolt
on rear axle
(point A)

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2009 Release

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

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

4.3.2 GEOMETRY VARIATIONS

Roll center height variation

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

Per-wheel camber variation

-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

Per-wheel alignment variation

0
-55 -45 -35 -25 -15 -5 5 15 25 35 45 55 65 75 85
-0,1

-0,2
Alignment (°)

-0,3
C ompression Rebound
-0,4

-0,5

-0,6

-0,7

Suspension travel (mm)

0mm for 110 mm body height

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 2009 Release

4.3.3 ADJUSTMENT OF GEOMETRY

Body height

Body height is adjusted using the nut (1)

mounted on the extension (2).
1
Loosen the locknut (3).
Adjust body height by tightening or loosening
the nut. 2
Once the required height has been reached, 3
tighten the locknut.

Alignment and camber

1
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

No 10' 20' 30' 1° 10' 20' 30' 1°
77 11 160 77 11 160 77 11 160 77 11 160 77 11 160 77 11 160 77 11 160 77 11 160
shim 176 175 174 173 172 171 170 169
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.

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2009 Release

4.3.4 REAR LOAD-BEARING COMPONENTS

Hub

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

Damper system

- Removal

Operations Photos

Place the vehicle on a jack stand on the appropriate

1-
side.

2 - Remove the wheel.

3 - Remove the lower mounting bolt (1).

1

4 - Remove the upper mounting nut (2).

5 - Remove the damper system. 2

- Refitting

Perform the removal steps in reverse order.

Tightening torques:
 Lower mounting bolt: 105Nm.
 Upper mounting bolt: 80Nm.

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2009 Release

- 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.

Remove the lower attachment (1) of the two

2- 1
shock absorbers.
2

3 - Remove the brake hoses from the calipers.

Support the rear axle and then remove:

4-  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.

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2009 Release

- Disassembly

Operations Photo

Remove the point A bolt (1) and collect the 2

1-
spacers (2).

1
2 - Remove the snap ring. 3

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.

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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

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.

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2009 Release

- Removal

Operations Photos

1 - Place the vehicle on an auto-lift.

Remove the front wheel on the relevant

2-
side.
1

3 - Loosen the alignment locknut (1).

4 - Remove the point H nut (2).

2
Extract the ball joint from point H using
5-
the tool: (1) Tav. 476.

6 - Remove the small bellows clamp (1). 2

7 - Cut the large bellows clamp (2). 1

Unscrew the steering tie-rod counter-

8 - clockwise and note the number of
rotations for refitting.

9 - Remove the steering tie-rod. 3

10 - Extract the bellows (3).

11 - Unlock the steering column.

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

12 -
steering bar, pinion side.

Release the axial ball joint using the (2)

13 -
Dir 1305-01 tool.

1
Remove the axial ball joint and steering
14 -
unit shim (1) (Ref 77 11 160 142).

- Refitting

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2009 Release

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

1
2

Tightening torques:
 Axial ball joint on bar: 80Nm.
 Point H nut: 37Nm.
 Steering tie-rod locknut: 53Nm.

Steering unit

- Removal

Operations Photos

Remove the subframe (see 4-2 Front 1

1 - axle/Front load bearing components/
Subframe).

Remove the two steering unit

2-
mounting bolts (1).

Remove the steering unit and collect

3-
the unit’s riser shims (2). 2

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2009 Release

- 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.

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).

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2009 Release

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).

Remove the intermediate shaft bolt (8) on the

5-
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.

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2009 Release

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.

Remove the steering wheel, followed by the wheel

5-
hub, after marking their initial positions.

6- Extract the bell from the folding yoke (1).

Remove the 2 roll cage stay bolts (2) on the

7-
steering sheath.
3
Remove the 2 sheath mounting bolts (3) on the
8-
column.

9- Remove the column sheath.

2

10 - Remove the extinguisher jet attachment lug (4).

Remove the 4 steering column bolts (5) on the

11 -
roll cage crossmember.
Remove the column, power steering module and
12 -
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
5
Steering/EPS unit).

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2009 Release

- 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.

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2009 Release

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.

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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.

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2009 Release

- Removal

Operations Photo

Remove the steering column (see previous

1-
paragraph).

Remove the 4 unit mounting bolts (1) on the

2-
steering column. 1
Remove the power steering module from the
column.

Note: keep the four spacers.

3-
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
1-
11 160 149).
2 - Tighten the 4 bolts (1) to 6Nm.

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

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2009 Release

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

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.

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2009 Release

4.5.2 FRONT BRAKES

Brake pads

- Removal

Operations Photos

Push back the pistons.

1-
Watch out for rising brake fluid levels in the
tank.

Remove the upper spindle (1) using a drift

2-
punch.

1
3 - Remove the spring and lower spindle (2).
2

Remove the pads, noting their position for

4-
refitting, where appropriate.

- Refitting

Perform the removal steps in reverse order.

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2009 Release

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

Disconnect the banjo bolt (1) linking the hose to

1-
the caliper (brake fluid will pour out).

2 - Remove the brake pads (see previous paragraph). 1

2
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.

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2009 Release

Disk

- Removal

Operations Photos

Push back the pistons.

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

Release the caliper and attach it in the wheel arch.

3-
Do not damage the hose (1).

3
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.

Press the brake pedal several times in order to place the piston in contact with the
5-
pads.

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2009 Release

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.

Push caliper piston back into its bore using the Fre
3-
1190-01 tool.

4 - Fit the pads.

Swivel the caliper downwards into its initial

5-
position.
6 - Refit a NEW small column bolt.
7 - Tighten the small column bolt to 32Nm.

- 42 -
2009 Release

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.

Remove the brake hose (2).

2-
Allow for fluid discharge.

Remove the small column mounting bolts (3) while

3-
holding the nuts (4).

4 - Remove the caliper.

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2009 Release

- 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.

Tightening torques:
7-  Small column bolts: 32Nm.
 Brake hose: 14Nm.

Hub disc

- Removal

Operations Photos

1 - Release the spindle bolt (1).

1 2
2 - Remove the wheel.

3 - Remove the brake pads (see previous paragraph).

4 - Remove the two brake caliper mounting bolts.

Remove the brake caliper and attach it in the wheel

5-
arch.

6 - Remove the spindle nut.

7 - Remove the hub disc (2).

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2009 Release

- 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.

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

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.

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2009 Release

Master cylinder

- Removal

Operations Photos

2
Remove the air box (1) and intake pipe 1
1-
(2).

Drain the master cylinder tank with a

2-
syringe.

Remove the clutch master cylinder pipe

3-
(3).
3
Remove the brake pipes, taking care to
4- 5
catch any brake fluid discharge.

Remove the 2 master cylinder mounting

5-
bolts (4) on the amplifier.
Remove the master cylinder – tank
6-
assembly. 4
Remove the master cylinder tank mounting
7-
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.

- 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

1 - Remove the air box and intake pipe.

1

Remove the check valve at the amplifier lever

2-
(1).

Remove the master cylinder (see previous

3-
paragraph).

Remove the dual safety coupling shaft (5)

4 - between the braking amplifier thrust rod and the
brake pedal.

5 - Remove the braking amplifier mounting nuts (9)

6 - Remove the braking amplifier.

Remove the braking amplifier spacer mounting

7-
bolts (10).

8 - Remove the braking amplifier spacer.

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2009 Release

- 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.

Pull and rotate the valve to release it from the rubber

2-
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.

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2009 Release

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:

60

50
Rear pressure
Pressure fully open
(bar) 40
Rear pressure
30
fully closed
20 Front pressure
10

0
Force applied to pedal

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).

- 50 -
2009 Release

Removal

Operations Photos

Unscrew the connectors (1) (allow for brake fluid

1-
discharge).
1

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

- Refitting

Operations Photos

Fit the wastegate on the support using the two bolts

1-
(2).
Place the connector ends in the wastegate’s threaded Output
holes. Initiate threading manually.
2-
Note: Follow the direction of assembly.
2
3 - Tighten the connectors to 13Nm.
Input
4 - Drain the braking circuit.
Preset the wastegate to the centre position: 15 “clicks"
5-
from one of the 2 end positions.

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2009 Release

4.6 WHEELS AND TYRES

4.6.1 CHARACTERISTICS

Wheels

Material: Aluminum/magnesium alloy.

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

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 S9B P2E
Type
Rear S9B P2E
Front 20/61-17 20/61-17
Dimensions
Rear 20/61-17 20/61-17

Cold inflation Front 1.6* 1.7*

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.

- 52 -
 2009 Release

4.7 KIT EVO 2009

4.7.1 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: Point B bolt :

Screw : 77 11 162 527 Screw : 77 11 156 908

Under head washer : 77 11 156 931 Under head washer : 77 11 156 931
Locknut : 77 03 034 115 Locknut : 77 03 034 115
Tightening torque : 80 N.m Tightening torque : 80 N.m

- 53 -
2009 Release

4.7.2 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.

4.7.3 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)

- 54 -
2009 Release

- 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) :

4.7.4 FRONT HEADLIGHTS

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

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

- 55 -
2009 Release

- 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!

4.7.5 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.

- 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 :

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:

- 57 -
2009 Release

- 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.

- 58 -
2009 Release

- 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:

- 59 -
2009 Release

4.8 TIGHTENING TORQUES

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

Connecting torque rod mounting bolt on

105
subframe

Bolts for points P and P’ 120

QQ’ tie-rod mounting bolts to body 105
QQ’ tie-rod mounting bolts to subframe 80

- 60 -
2009 Release

Anti-roll bar tie-rod mounting bolts 44

Point H nut 37
Anti-rotation tie-rod mounting bolt on
100
wishbone
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
105
crossmember
Sheath bolt 21
Sheath mounting bolt on roll cage stays 21
Intermediate shaft mounting bolt on column 34
Wheel hub bolt 44

- 61 -
2009 Release

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

- 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

(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

Nut for bearing mounting bolt on rear
(7) 125
axle

- 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


2009 Release




5 WIRING AND ELECTRICAL EQUIPMENT






3235



5 WIRING AND ELECTRICAL EQUIPMENT 1

5.1 FRONT OF THE CAR 2

5.1.1 PIN-OUT 2
5.1.2 WIRING DIAGRAM 4
5.2 ENGINE 5
5.2.1 PIN-OUT 5
5.2.2 WIRING DIAGRAM 8
5.3 DRIVER COMPARTMENT 9
5.3.1 PIN-OUT 9
5.3.2 WIRING DIAGRAM 20
5.4 EXTINGUISHER 21
5.4.1 PIN-OUT 21
5.5 DATA ACQUISITION KIT - CIRCUIT DIAGRAM 22
5.5.1 PIN-OUT 22
5.5.2 WIRING DIAGRAM 23
5.6 OTHER ELECTRICAL EQUIPMENT 24
5.6.1 NEW TECHNOLOGY BATTERY MASTER SWITCH 24
5.6.2 CIRCUIT-BREAKER 24
5.6.3 POWER RELAYS AND FUSES 25

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- 25 -
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DATA ACQUISITION
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6 DATA ACQUISITION






3235

6 DATA ACQUISITION 1

6.1 OPERATING SOFTWARE 2

6.1.1 PRESENTATION 2
6.1.2 ETHERNET COMMUNICATIONS 2
6.1.3 COMMUNICATION WIRE 4
6.1.4 VISION 4.17.08 LITE APPLICATION 6
6.1.5 WINTAX 3 JUNIOR APPLICATION 10
6.1.6 ACQUISITION TABLE 15
6.2 DATA ACQUISITION KIT 17
6.2.1 PRESENTATION 17
6.2.2 MAIN ADDITIONAL CHANNELS AVAILABLE ON WINTAX3 17
6.2.3 KIT CONTENTS 17
6.2.4 KIT INSTALLATION 20
6.2.5 PROCEDURE FOR RESETTING THE ACCELEROMETER AND BRAKE
PRESSURE SENSORS 23
6.2.6 TRACKSIDE BEACON 23

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