E30 Zone

Is there any easy way of working out what length spacer is needed when using a Clio servo or is it a bit of a trial and error job?

Trial and error which is why I wont sell them

as dan says it's all trial & error, also depends om what M/C your using.
i used a 25mm from an audi (can't remember which model sorry) & all i had to do was adjust the rod from the pedal to the clevis pin & it fitted spot on.

rule of thumb is the "spacer" is either 10mm or 20mm, make up one of each length & go from there.

Thanks chaps. Will see how I get on tomorrow. Feels a bit weird to rely on a Clio component to stop a relatively powerful car though.

Do you have any plans to do a plug and play solution any time soon Dan?

They made Clio’s with more power than 325i e30’s !

Gt40e30 wrote: ↑

Sun Jan 27, 2019 11:16 am

They made Clio’s with more power than 325i e30’s !

Yes but the Clio V6 had a different servo to the 1.2!
https://www.ebay.co.uk/itm/Renault-Spor ... 2458417823

The servo is made by Bosch and is much more modern, ive fitted just a servo before and the brakes become much better.
You cant plug and play servos, they are much too reliant on final adjustment, ive seen and repaired some horrendous bodges over the years where servos are concerned, id rather not sell anything to do with them

So with the bits in front of you, how would you determine the spacer size? Enough to fully fill the gap without slack or preload?

I just done mine this weekend. Can post up some pics I took if that helps.

Pedal feels a lot firmer compared to the standard set up.

I'm getting a noticeable servo noise inside the car now when I press the brake pedal though - it's been so long since I have driven the car that I can't remember whether the E30 servo could be heard inside the car as well. I think it did, but can't remember!

Does anyone have a part number?

Rinx wrote: ↑

Sun Mar 24, 2019 6:54 pm

I just done mine this weekend. Can post up some pics I took if that helps.

Pedal feels a lot firmer compared to the standard set up.

I'm getting a noticeable servo noise inside the car now when I press the brake pedal though - it's been so long since I have driven the car that I can't remember whether the E30 servo could be heard inside the car as well. I think it did, but can't remember!

Did you use a spacer?

I used a spacer in mine, just finished bleeding the brakes so will find out if its worked or not when I start the car next. Currently the pedal is rock solid, no movement! Is this a sign I didnt need a spacer??

I think the part number is 8200 192 616. You need a servo from a mk2 clio 1.2 so 2001 to 2005. The one I have is a Bosch one which is approximately 220mm wide. There is an ATF one on certain Clio's which I think is too wide.

JoeyB - yes, I did have to use a spacer. On the E30 servo that I removed, the push rod sits flush with the face of the servo where the master cylinder mounts. On the clio servo, the push rod was shorter so I measured the distance from the top of the push rod to the face of the servo which was 23mm. I made a spacer up to this length by cutting a steel rod with an angle grinder and then rounding the top off. I also put a dimple in the bottom using a drill bit. The final length of the spacer was just under 23mm.

Did you adjust the rod that goes between the brake pedal and the clevis pin? I had to release it first so the servo could be connected up with the clevis pin and then tightened the rod (i.e. screwed it in at the pedal) until I was happy with the pedal feel. I found that if you tighten even slightly too much, the brakes bind so it took a bit of messing around to get it right. Sounds like you need to start the car when it's ready and then see what the brake pedal feels like. If it is still rock hard, then maybe release the rod a bit from the pedal and see if that helps.

Hope that makes sense.

Turns out I didnt have the push rod located in the master cylinder...must have slipped past when tussling to get the MC over the two mounting studs. I've also managed to lose two spacers now in the brake servo. No idea how I'm managing that but they are clearly rattling free whilst fitting. Going to take the servo off again and hopefully retrieve two spacers currently MIA

Have you tried using a telescopic magnet tool?

Rinx wrote: ↑

Mon Apr 15, 2019 7:54 pm

Have you tried using a telescopic magnet tool?

i've used one of them a few times when i've dropped nuts in the engine bay & they've saved my skin a few times.

well worth a few quid to try & fish out any "lost" nuts/washers.

Rinx wrote: ↑

Mon Apr 15, 2019 7:54 pm

Have you tried using a telescopic magnet tool?

Looks like the spring in the servo will prevent me from getting the magnet where I want it. Its not much bother to take the servo all the way out. This time I'll refit with MC connected so I'm confident the spacer doesnt get lost! New MC going in also...

i've found that a flat headed slim & flexible magnetic pick up tool is a god send in the tool box,

what M/C you going to be using?

Yes my magnetic pickup tool is a bit clunky, probably worth an upgrade as you say

Just using the standard E30 MC, new one is Topran I think

dont blame you with the new M/C,
when i did mine i changed it to a 25mm non abs one from an audi just had to block off the two outlets on the other side using bleed nipples,

Did the brakes improve with the Audi M/C?

Rinx wrote: ↑

Tue Apr 16, 2019 8:16 pm

Did the brakes improve with the Audi M/C?

Yes quite a bit,

I used the audi M/C with the clio servo,
But because I've got 284mm disc's with 4 pot calipers as well I had to make use of an adjustable bias Valve in the rear line to stop the rear brakes locking up.

Is that the WMS setup?

I’ve got that to put on yet. Just want to see standard brakes working before introducing more change !

no mine is the hi spec billet 4 set up, had it about 10yr's.

if i need new discs i use mg zr 160 front discs. (cheaper than what hi-spec/ebc want)

Ah OK. Supposedly the WMS setup is well suited to the standard M/C so hopefully I'll be OK with what I have

joeyb wrote: ↑

Wed Apr 17, 2019 11:16 am

Ah OK. Supposedly the WMS setup is well suited to the standard M/C so hopefully I'll be OK with what I have

My set up was pretty good with the standard m/c as well.

I upgraded it when I did the clio servo conversion (diaphragm had gone in the e30 servo).

I whipped the servo off tonight and retrieved the two MIA spacers lol. This time I joined the M/C and servo on the bench and then refitted as a complete unit. No more missing spacer! I'll bleed things up when I next get out to the garage and see whats what. When I'm happy with standard setup I'll get the WMS parts fitted.

sounds like a plan, good luck.

Got my brakes on and bled tonight. Brake pedal goes almost to the floor then bites. Can hear the servo whooshing during the pedal travel. Does this mean I haven’t bled it properly or my spacers needs work?

Sorted. Had to bleed them again and then adjust linkage as brakes were binding. All good now.

I took my M/C off and the push rod from the servo has sheared off! Need to track down a new servo now. Sorting these brakes out is taking far too long!

What I might do this time is buy a threaded rod which is the right pitch/thread as the clio one and just replace the push rod so I dont need a spacer.

How has the rod sheared?? Reckon you didn’t locate it properly during install? I had that first time I tried. Found it easier in the end to take everything off the car and build on the bench.

Yeh, I think it wasn't located properly when I fitted the master cylinder as the brakes pipes were still connected so it was a bit all over the place.

I spent ages sanding down the servo and painting it so it is a bit annoying! I will disconnect the master cylinder and fit it before bolting up the servo as you have suggested.

Is yours back on the road now - how is it running?

Booking MOT this week now that I’ve finally managed to bleed clutch and brakes.

I’ve got brand new Bosch calipers on rear and new to me WMS 4 pot setup on the front with braided lines. I also replaced brake master cylinder. I guess that’s why it took me a while to get it all bled up!

Brake pedal feels good on my driveway. Once I had it bled I then found front brakes binding on so had to get involved with the lever adjustment, wasn’t too difficult though.

I’ll let you know how the drive to the MOT station goes lol

Sounds like a good setup! Good luck with the MOT

I'm having a really hard time finding a Renault Clio Mk2 1.2 (2001-2005) brake booster ready for my M52 swap. Have these become like hens teeth now or something?

If I put in the right car details into something like autodoc, it seems to return a selection of new 9 inch brake servos at not crazy prices. But they don't seem to match the part number shared earlier in the thread. Any reason one of these wouldn't just work?

https://www.autodoc.co.uk/bosch/8443989