User's Manual

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USER MANUAL

E. Chassis

Summary of content (69 pages)

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USER MANUAL E.
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010 Release 4 CHASSIS CONTENTS 4 CHASSIS 2 4.1 SETUP 4.2 FRONT AXLE 4.2.1 PRESENTATION AND CHARACTERISTICS 4.2.2 GEOMETRY INSPECTION 4.2.3 GEOMETRY VARIATIONS 4.2.4 ADJUSTMENT OF GEOMETRY 4.2.5 FRONT LOAD-BEARING COMPONENTS 4.2.6 WHEEL PASSAGES 4.3 REAR AXLE 4.3.1 PRESENTATION AND CHARACTERISTICS 4.3.2 GEOMETRY VARIATIONS 4.3.3 ADJUSTMENT OF GEOMETRY 4.3.4 REAR LOAD-BEARING COMPONENTS 4.4 STEERING 4.4.1 STEERING UNIT 4.4.2 INTERMEDIATE SHAFT 4.4.3 STEERING COLUMN 4.4.4 ELECTRIC POWER SYSTEM 4.
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2010 Release 4.1 SETUP The following Clio Cup settings apply with a 70kg driver and 40kg of fuel on board.
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2010 Release 4.2 FRONT AXLE 4.2.1 PRESENTATION AND CHARACTERISTICS The front axle is a double axis strut type suspension system.
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2010 Release Damper system z-axis y-axis Anti-roll bar tie-rod Support strut Pivot Pivot holder Point E’ bolt EE’ support Point E Point F’: Pivot to pivot holder mounting ball joint Roller bearing Hub Caliper Disk E-5
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2010 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.
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2010 Release 4.2.2 GEOMETRY INSPECTION Body - height points measurement 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. - Front body height Rear body height Measuring the front body height The front body height is measured at the level of the lower front wishbone mounting (1).
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2010 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.
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2010 Release 4.2.
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2010 Release 4.2.4 ADJUSTMENT OF GEOMETRY Body height 1 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. 2 Wheel alignment 1 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.
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2010 Release 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 Photos Operations 1 - Remove the wheel.
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2010 Release - Disassembly Operations Photos Remove the upper nut, holding the shock absorber with a hexagonal socket wrench. 1- 1 2 - Remove the snap ring (1). Loosen the nut (5) and locknut (6) so that the spring is relaxed (3). 3- Remove the retainer ring (2) from the 4spring cup. 5 - Remove the suspension spring cup (3). 2 3 4 6 - Remove the suspension spring (4).
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2010 Release 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.
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2010 Release EE’ support - Removal Operations Photos 1 - Remove the wheel. 3 2 - Remove the point E nut (1). Extract the EE' support from the point E ball joint; a ball joint puller must be used to do this. 3- 4 - Remove the point E’ ball joint mounting bolt (2). 2 1 Remove the 3 EE’ support mounting bolts on the 5pivot holder (3). 6 - Remove the EE’ support. - Refitting Perform the removal steps in reverse order. Tightening torques:  Point E’ mounting bolt: 26.5Nm.
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2010 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.
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2010 Release Subframe - Removal Operation 1- Photos 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. 2 3 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).
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2010 Release 7- 5 Disconnect the anti-rotation tie-rods at the level of the wishbones (5). 7 Disconnect the steering tie-rods at the level 8of 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 - 6 Remove the bolts from points P (9) and P’ (10). 9 12 - - Extract the subframe hydraulic plate.
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2010 Release Steering unit mounting bolt ref.: 77 03 602 136 Steering unit ref.: 77 11 160 046 Steering unit riser shims ref.
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2010 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.
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10 Release 4.2.6 WHEEL PASSAGES The wheel passages are in 2 parts, a rear one and a front one.
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2010 Release 3 Fix the plastic mounting clamps (right side on photograph) 4 Tight this 3 screws under the protective moulding behind the wheel 5 Fix a plastic collar between the front wheel passage and the plastic plate for engine protection Perform the assembly steps in reverse order to remove it.
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2010 Release 4.3 REAR AXLE 4.3.1 PRESENTATION AND CHARACTERISTICS The rear axle has combined swingshafts.
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2010 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 Force [daN] : Nominal 5 0 ---- : Tolerance 0 0 0.0 5 0.
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2010 Release 4.3.
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2010 Release 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. 1 2 3 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.
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2010 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 side. 1- 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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2010 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 shock absorbers. 2- 1 3 - Remove the brake hoses from the calipers. Support the rear axle and then remove:  The six bearing mounting bolts (2).  The rear axle.
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2010 Release - Disassembly Operations Photo Remove the point A bolt (1) and collect the spacers (2). 1- 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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2010 Release 4.4 STEERING Power steering module Steering column Steering tie-rod ball joint Intermediate shaft Folding yoke Steering tierod Steering unit Bellows 4.4.1 STEERING UNIT Axial ball joint Specialist tools  Dir. 1305-01  Dir. 1741  TAV 476 Axial ball joint removal-refitting tool. Steering unit bar retainer tool. Ball joint puller. The axial ball joint is replaced with the steering unit in place on the vehicle. Indeed, the Dir. 1741 or Dir.
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2010 Release - Removal Operations Photos 1 - Place the vehicle on an auto-lift. 2- Remove the front wheel on the relevant side. 1 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. 2 2 6 - Remove the small bellows clamp (1). 7 - Cut the large bellows clamp (2). 1 Unscrew the steering tie-rod counter8 - clockwise and note the number of rotations for refitting. 3 9 - Remove the steering tie-rod.
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2010 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. 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).
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2010 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.
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2010 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 column. 5- 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.
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2010 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. 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.
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2010 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.
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2010 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.
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2010 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)).
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2010 Release - Removal Operations Photo 1- Remove the steering column (see previous paragraph). 2- Remove the 4 unit mounting bolts (1) on the steering column. 1 Remove the power steering module from the column. Note: keep the four spacers. 3It 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 1- Refit the power steering module on the column, using the 4 spacers (ref 77 11 160 149).
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2010 Release 4.5 BRAKING SYSTEM 4.5.1 CHARACTERISTICS Front brake     Rear brake     Clutch slave cylinder diameter: 40mm. Disc diameter: 312mm. Disc thickness: 28mm. Minimum disc thickness: 26mm. 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.
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2010 Release 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).
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2010 Release 4.5.2 FRONT BRAKES Brake pads - Removal Operations Photos Push back the pistons. 1- 2- Watch out for rising brake fluid levels in the tank. Remove the upper spindle (1) using a drift punch. 1 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.
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2010 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 the caliper (brake fluid will pour out). 1- 2 - Remove the brake pads (see previous paragraph).
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2010 Release Disk - Removal Operations Photos Push back the pistons. 1- Watch out for rising brake fluid levels in the tank. Remove the two bolts (2) holding the caliper on the 2pivot. 1 2 Release the caliper and attach it in the wheel arch. Do not damage the hose (1). 3- 4- Remove the two disc mounting bolts (3). 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).
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2010 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. 3- Push caliper piston back into its bore using the Fre 1190-01 tool. 4 - Fit the pads. 5- Swivel the position.
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2010 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. 2- 3- Remove the brake hose (2). Allow for fluid discharge. Remove the small column mounting bolts (3) while holding the nuts (4).
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2010 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. 7- Tightening torques:  Small column bolts: 32Nm.  Brake hose: 14Nm. Hub disc - Removal Operations Photos 1 - Release the spindle bolt (1). 1 2 - Remove the wheel.
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2010 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 pads. 7- - Checking play Check axial play using a dial gauge mounted on the disc: max. 0.03 mm.
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2010 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.
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2010 Release 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). 2 3 Remove the brake pipes, taking care 4to catch any brake fluid discharge. 5- Remove the 2 master cylinder mounting bolts (4) on the amplifier. 6- Remove the master cylinder – tank assembly. Remove the master 7mounting bolt (5). cylinder 5 4 tank 8 - Remove the master cylinder tank.
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2010 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 2- Remove the check valve at the amplifier lever (1). 3- Remove the paragraph). master cylinder (see previous Remove the dual safety coupling shaft (5) 4 - between the braking amplifier thrust rod and the brake pedal.
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2010 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.
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2010 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.
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2010 Release Removal Operations Photos Unscrew the connectors (1) (allow for brake fluid discharge). 1- 1 2 2 - Remove the mounting bolts (2) and the wastegate. - Refitting Operations 1- 2- Photos Fit the wastegate on the support using the two bolts (2). Place the connector ends in the wastegate’s threaded holes. Initiate threading manually. Output Note: Follow the direction of assembly. 2 3 - Tighten the connectors to 13Nm. Input 4 - Drain the braking circuit.
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2010 Release 4.6 WHEELS AND TYRES 4.6.1 CHARACTERISTICS Wheels Material: Aluminum/magnesium alloy. A B Wheel type Width (inches) Wheel profile 8J×17 8 J rim C Nominal  under tyre bead (inches) 17 D E Number holes of 5 ET offset 68 Maximum offset: 0.3mm measured on the wheel rim. Maximum out-of-round: 0.3mm measured on the tyre bead bearing surface.
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2010 Release KIT EVO 2009 4.7.
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2010 Release 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.
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2010 Release 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.
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2010 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) : 4.7.5 FRONT HEADLIGHTS The front headlights directly take place instead of the old ones.
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2010 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! 4.7.6 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.
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2010 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.
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2010 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 antifog 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.
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2010 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.
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2010 Release 4.8 TIGHTENING TORQUES Tightening torques in Nm Specific recommendations Wheel studs 100 Copper grease Wheel nuts 110 Parts FRONT AXLE Wheels 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 Pivot holder 105 Point E nut 105 EE’ support Mounting bolt on pivot holder 140 Ball joint E’ mounting bolt 26.
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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 Nut for bearing mounting bolt on rear axle 62 125 Plate spindle on axle 71 Brake hose nut 14 STEERING Axial ball joint Axial ball joint 50 Point H
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2010 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 Rea
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2010 Release 13 6 8 14 9 7 10 12 4 5 11 1 3 2 Parts Tightening torque in Nm (1) Point A bolt 80 (2) Point B bolt 80 (3) EE’ support nut on wishbone (point E) 105 (4) EE’ support bolt on pivot holder 105 (5) EE’ support bolts on pivot (point E’) 26.
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2010 Release 14 15 19 20 16 18 17 Parts Tightening torque in Nm (14) Anti-roll bar mounting bolt on tierod 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 E-67 Specific recommendations
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2010 Release 6 1 3 2 4 5 7 Parts Tightening torque in Nm (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 (7) Nut for bearing mounting bolt on rear axle 14 125 E-68 Specific recommendations
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2010 Release 2 3 4 5 1 Parts (1) Folding yoke cam bolt (2) Column mounting bolt on roll cage crossmember (3) Sheath bolt (4) (5) Tightening torque in Nm 24 105 21 Sheath mounting bolt on roll cage stays Intermediate shaft mounting bolt on column 21 34 E-69 Specific recommendations