technical manual - SEAT Motorsport Italia

technical manual - SEAT Motorsport Italia
LEON CUP RACER
2015
TECHNICAL MANUAL
TECHNICAL MANUAL LEON CUP RACER
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TECHNICAL MANUAL LEON CUP RACER
Table of contents
1
2
3
4
TECHNICAL INFORMATION ........................................................................................... 4
1.1
Leon Cup Racer Display............................................................................................ 4
1.2
Dimensions and weights............................................................................................ 5
1.3
Body shell .................................................................................................................... 6
1.4
Powertrain .................................................................................................................... 7
1.5
Rim & Tire .................................................................................................................... 9
1.6
Electronic units ............................................................................................................ 9
DRIVERS CONTROL ...................................................................................................... 11
2.1
Main console ............................................................................................................. 11
2.2
Steering wheel module ............................................................................................ 11
2.3
Gear lever functions ................................................................................................. 12
2.4
Car launching systems ............................................................................................ 13
2.5
Speed limiter system ................................................................................................ 14
2.6
Driver has to consider .............................................................................................. 15
DISPLAY & FUSE BOX ................................................................................................... 16
3.1
Display alarms and shift lights ................................................................................ 16
3.2
Data acquisition analysis ......................................................................................... 18
3.3
MXG channel expansion scheme .......................................................................... 19
3.4
Fusebox ..................................................................................................................... 21
3.5
Auxiliary connectors ................................................................................................. 24
SETTING ADJUSTMENTS ............................................................................................. 27
4.1
Delivery car set-up.................................................................................................... 27
4.2
Steering rack centering ............................................................................................ 28
4.3
Suspension adjustments ......................................................................................... 28
4.4
Front Camber and Toe adjustment ........................................................................ 29
4.5
Rear Camber and Toe adjustment ........................................................................ 29
4.6
Dampers ...................................................................................................................... 31
4.7
Antiroll bars ................................................................................................................ 34
4.8
Kinematics ................................................................................................................. 34
4.9
Brakes ........................................................................................................................ 36
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TECHNICAL MANUAL LEON CUP RACER
4.10
5
Aero ............................................................................................................................ 37
WORKSHOP MANINTENANCE .................................................................................... 38
5.1
FIRST ROLLOUT ..................................................................................................... 38
5.2
Check list ................................................................................................................... 38
5.3
Vehicle & parts identification ................................................................................... 39
5.3
Fluids information ..................................................................................................... 40
5.4
Engine service........................................................................................................... 41
5.5
Air filter ....................................................................................................................... 41
5.6
Gearbox & Slip differential service ......................................................................... 43
5.7
FDX - Slip differential control & service................................................................. 43
5.8
Fuel ............................................................................................................................. 44
5.9
Electronic modules ................................................................................................... 45
5.10
Airjack ......................................................................................................................... 46
6
PARTS MILEAGE............................................................................................................. 47
7
SAFETY ............................................................................................................................. 48
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TECHNICAL MANUAL LEON CUP RACER
1
TECHNICAL INFORMATION
1.1
Leon Cup Racer Display
Engine
\ Type
\ Fuel supply system
\ Displacement (cc)
\ Bore and stroke (mm)
\ Maximum power (PS/rpm)
\ Maximum torque (Nm/ rpm)
\ Electronic control unit
\ Exhaust / dB.
\ Fuel tank capacity
\ Speed limiter system
\ Launch control system
Turbocharged; 4-cylinder in line
Direct fuel injection
1984 cc
82,5 x 92,8
330 PS
410Nm
Continental SIMOS
Racing catalysed 104dB
55 lts Standard tank with additional
active 60km/h
active
Transmission
\ Transmission
\ Gearbox
\ Differential
\ Clutch
\ Shift control
Front-wheel-drive
6 speed DSG
VAQ ellectronically managed
Multi disc oil cooled
Electronic on steering wheel
Chassis and Suspension
\ Front suspension
\ Anti-roll bar
\ Rear suspension
\ Front brakes
\ Rear brakes
\ Brake pedal
\ Steering system
\ Rims
\ ABS
Body and aerodynamics
\ Roll bar Driver position
\ Weight
\ Front Width (max)
\ Rear Width (max)
\ Length
\ Wheel base
Car check-control
\ Acquisition system
\ Car check-control
\ Airjack
McPherson, adjustable in height, toe and camber
Front and rear adjustable
Multi-link axel, adjustable in height, toe and
camber
6-piston callipers, 362 mm steel ventilated discs
272 mm steel discs
Unitary with brake balance regulation
Full Ellectrical power steering rack
Removed
FIA Homologated and Hans adapted
1.120 kg
1.950 mm
1.950 mm
4.363 mm
2.666 mm
AIM - MXG 28 channels + 8 analogics
Auto-diagnosis OBDII / DiagRA - LE
Complete car kit
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TECHNICAL MANUAL LEON CUP RACER
1.2
Dimensions and weights
Dimensions
Overall length
Overall bodywork front width
Overall bodywork rear width
Wheel base
Over hang front splitter
Over hang front bumper
Over hang rear
Over hang rear wing
Minimum ground clearance
4382 mm
1950 mm
1950 mm
2665 mm
897 mm
868 mm
820 mm
165 mm
free
Weight:
Total weight in race conditions without fuel
Car balance
Distribution weight/power
Measured on the mud-ward at the front axle
Measured on the mud-ward at the rear axle
From the wing vertical to the bumper
70 mm is the performance recommendation
1150 Kg (1)
63,2% front <> 36,8% rear
3,48 Kg/cv
Note:
(1) This value means the minimum weight on the “Technical Regulations” in race conditions.
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TECHNICAL MANUAL LEON CUP RACER
1.3
Body shell
PART NUMBER
01
02
03
04
05
11
12
13
14
15
16 (2014)
16 (2015)
17
18
19
21
22
23
24
25
DESCRIPTION
BONNET
LEFT / RIGHT FRONT BONNET
LEFT RIGHT REAR BONNET
ROOF
LUGGAGE COMPARTMENT COVER
BONNET OPPENING
FRONT SPLITTER
FENDER AIR EXIT
FRONT BUMPER
REAT BUMPER
LEFT /RIGHT SILL TRIM PANEL
LEFT /RIGHT SILL TRIM PANEL
LEFT / RIGHT REAR DOOR EXTENSION
LEFT
/
RIGHT
REAR
FENDER
EXTENSION
LEFT / RIGHT FRONT FENDER
MATERIAL
STEEL
STEEL
STEEL
STEEL
STEEL
CARBON
CARBON
CARBON
FIBER GLASS
FIBER GLASS
PLASTIC
FIBER GLASS
CARBON (painted)
WINSCREEN
LEFT / RIGHT FRONT DOOR WINDOW
LEFT / RIGHT REAR DOOR WINDOW
LEFT / RIGHT REAR TRIANGLE
WINDOW
REAR WINDOW
GLASS
GLASS
GLASS
CARBON (painted)
CARBON (painted)
PLASTIC
PLASTIC
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TECHNICAL MANUAL LEON CUP RACER
1.4
Powertrain
Engine
ENGINE FEATURES
Type
Engine identification
Cylinder capacity
Corrected cylinder capacity
Maximum power
Maximum torque (Nm/ rpm)
Max rpm
Specific Power
Electronic control unit
Fuel
Fuel Consumption
Exhaust / dB
Distribution
Oil system
Water pump
Water thermostat
Fan range
Standard Fuel tank features
Fuel tank type
Capacity
Minimum fuel level before engine
fault
2,0 TSI / Turbocharged & direct injection
CJX
1984 cc
1984 x 1,7 = 3372,8
242 KW (330 Hp) at 6250rpm
410 Nm at 4600 rpm
6800 rpm
165 CV/l
CONTINENTAL SIMOS 18.1
RON MIN 98 , RON MAX 102
0,37 to 0,42 l/km
Racing Catalyst FIA Homologated / 104 dB
Chain (sealed)
Wet sump
One electric water pump + two auxiliary pumps
Double electronic thermostat
Operating range 92°C to 87°C
Standard fuel tank from Quattro version
55 lts Standard tank
> 5 lts.
Engine power and torque curve:
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TECHNICAL MANUAL LEON CUP RACER
Gear box & Slip diff.
Gear box features
Transmission
Gear box
Differential
Differential settings
MAP 1
MAP 2
MAP 3
Clutch
Gear box mode command
Gear shift
Gbx. Electronic Control Unit
Cooling system
Launch control system
Down shift over rev protection
Front wheel drive
6 speed DSG (semi automatic gbx)
VAQ Electronic slip differential
3 Map available.
Map swapping through the steering wheel module green button.
Base mode, No OverSlip, Only yaw damping in speeds above
110km/h. 300 Nm prelock during braking.
Recommended use when grip is high. (new tyres or good grip)
Like map 1, less yaw damping, 200 Nm prelock during braking
Recommended use when medium grip. (used tyres)
Prelock dependent from engine torque, 200 Nm prelock during
braking(releasing earlier than 2)
Recommended use when grip is low or rain
Double multidisc clutch in oil bath
Electronic on the central gear lever
Paddles on the steering wheel
Integrated mechatronic in oil bath
Exchanger oil - water
Activated
Activated / 1sec memory
Gear box Ratios
GROUP 1-23-4
GROUP 5-6
15
72
0,208
83
180
189
20
72
0,278
RPM1
GEAR
SHIFT
CUT
FINAL RATIO
GEAR
1
Prim
Z1
13
22
28
38
32
38
1
Sec
Z2
38
45
41
41
35
35
1,000
Gear
Relation
0,342
0,489
0,683
0,927
0,914
1,086
3000
6500
6800
26
37
51
70
92
109
56
80
111
151
199
236
58
83
117
158
208
247
1st
2nd
3rd
4th
5th
6th
Total
Relation
0,071
0,102
0,142
0,193
0,254
0,302
DIF
Km/h
DIF
RPM
1952
1847
1711
1558
1026
8000
7000
6000
5000
4000
3000
0
20
40
60
80
100
120
140
160
180
200
220
240
260
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TECHNICAL MANUAL LEON CUP RACER
Supension
Features
Front damper ZF Sachs
Springs Eibach front and rear
Front Antiroll bar
Rear bumper ZF
Rear Antirollbar
Description
2 way adjustable / Aluminium body
160/60/70 -80-90-100-110
22x2 // 22x3
1 way adjustable parallel / Aluminium
body
22 x3 // 22x4
Brakes
Brake car features
Front caliper
Front disc
Front pump
Front pads
Rear caliper
Rear disc
Rear pump
Rear pads
Rear press reducer
Brake balance
1.5
Description
AP 6P
362 x 32
AP 19,1 mm
Pagid 5F6
AP 2P
272x10
AP 22,2 mm
Pagid 5F6
valve 25 bar
Mechanical
Remarks
Special: SEAT Sport
Special: SEAT Sport
Thick: 25 mm
Solid
Orange
(nominal)
Rim & Tire
Tyre information
Rim dimension
Rim centre lock
Maximum tyre dimension recommended
Tyre temp difference inside / outside
Minimum cold pressure recommended
1.6
Remarks
Click bmp10 / 20 Rebound
Adjustable
Adjustable in 6 positions
Click 20
10”x 18” ET 36
5 studs x 112 mm
270/660 R18
20ºC
1.4 bar
Electronic units
Electronic MODULES
ECU
Mechatronic
Electronic slip differential
Low fuel pump control
Electronic Steering rack
ESP unit
Gateway
Black box
MXG display / logger
Fuse box
Steering Driver module
Transponder
Remarks
Continental
VW
BorgWarner
PWM control
module
VW
Continental
VW
Audi
AIM
SEAT Sport
SEAT Sport
XXX
Software
Motorsport
Motorsport
Motorsport
Series
Place
Engine bay
Inside gear box
FDX (external)
Fuel tank (external)
Motorsport
No active
Series adapted
Motorsport
Motorsport
Motorsport
Motorsport
Front subframe
Cockpit
Cockpit
Cockpit
Cockpit
Cockpit
Cockpit
Engine bay
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TECHNICAL MANUAL LEON CUP RACER
Modules information
Mechatronic
Elec. Slip diff.
Low fuel pump
Steering rack
ESP
Gateway
Specific software/ mapping:
Specific codifications:
Interchangeable between cars:
Spare part ready for plug and play:
*UDS diagnosis (VW diagnosis):
Modification allowed:
Engine
MODULES BASED IN SERIES
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
No
No
Yes
No
Yes
Yes
No
Yes
Yes
No
No
No
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
No
No
yes
Yes
Yes
Yes
No
Yes
yes
Yes
Yes
Yes
No
Notes:


Use always spare parts from SEAT Sport. Although the mentioned parts are derived from series
cars, the software and codifications are different and modified for SEAT Sport.
OBD: All series modules used on the SEAT Leon Cup Racer are based in the MQB platform.
Through the diagnostic tool available on the VW Group dealers, it is possible to diagnostic any
malfunction.
Architecture Leon Cup Racer:
All electronic modules are connected by CAN Bus and LIN_Bus. Following the LCR CAN scheme view:
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TECHNICAL MANUAL LEON CUP RACER
2
DRIVERS CONTROL
In this section is explained how the driver can handle the Leon Cup Racer commands and functions.
2.1
Main console
Main switch:
Active the battery supply.
Ignition switch: Active the power to all devices.
Low beam:
Active the low beam light. High
beam and flash activation buttons are placed on the
steering wheel module.
Turn light:
Active the left and right turn lights.
No automatic return.
Brake balance: Turning the balance wheel you
can balance the brake pressure from front to back or
vice versa.
Do not press the brake pedal while moving the balance wheel.
Through the driver display you can check the front and rear brake pressure and the balance in
percentage.
Notes:

2.2
To start the engine, always proceed with this order: Main switch and later power supply. To stop the
engine proceeds backwards.
Steering wheel module
The electronic steering wheel module permits to
activate different functions without living hands
from the steering wheel.
Some buttons has double functionily
Steering wheel functions:
Nº
1
Function
Starter
Conditions / Remarks
Active in gear lever in “P” or “N”
Active if rpm < 500
Speed limiter
Pressing the button constantly limit 60 km/h
2
Diff map change
3 maps
3
Traction control
active/deactivate
Safety brake
signal button
Short push to increase differential map number
The diff map scrolls rotatory with 3 maps
Diff map number is showed on the display screen “driver 1”
Map 1: Us when grip is high. (new tyres or good grip)
Map 2: Use when medium grip. (used tyres)
Map 3: Use when grip is low or rain
ONLY WHITH ABS UNIT ACTIVE
Pressing the button 3 seconds the TCS can be deactivated.
“Brake signal can be activate with this button in case of brake switch
failure”
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TECHNICAL MANUAL LEON CUP RACER
4
Radio
5
Rain lights
Possible move the gear lever without push the brake pedal
IMPORTANT: the use of this security button it’s under the user
responsibility.
Driver voice activation
Maintain pushed to talk
Short push to toggle on/off
6
Driver fan
Toogle to activate
7
Change display
Press to change the display pages / rolling change
8
High beam
9
Wiper
Short push to flash
Long push to toggle on/off
Toggle to activate.
10
Windscreen water
Push to activate water splash + wiper activation
11
Drink
‘ -- +
Tip up // Tip
Activates water pump
Note: Pump not supplied by SSp
Orange led informs when tip up or down signal has been activated
down
CAN info
Usual status: LED off
LED on when there is a problem of CAN Bus communication
Notes:


Although it is possible uncouple completely the steering wheel from the column with the engine
running, is not advisable. (Cause fault messages on the OBD).
Be careful with the “Safety brake signal button”. This button permits put in Neutral the gear lever
although the brake pedal is not pressed. Take care and advise the people around the car
because wheels may move.

2.3
Gear lever functions
The shifting gear lever enables the different gear box modes. The features for each mode are:
Gear lever
Mode
Remarks
P
Parking mode
R
Reverse
Use to lock the car.
(Safety for team staff when car is
stopped)
(not allowed on the pits zone)
N
Neutral
No gear engaged. Traction is free.
D/S
Automatic mode
Tip + / - (TS)
Manual shifting
D= Automatic Drive
S= Automatic Sport Drive
Shifting through the wheel paddles
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TECHNICAL MANUAL LEON CUP RACER
“P” parking mode:
Use parking mode to lock the transmission trough a mechanical cable. Use only this position when you
want block the car.



It’s only possible lock or unlocks the parking mode if the car is completely stopped and the brake
pedal is pressed.
IMPORTANT: Never try to put the gear lever in “P” if the car is not completely stopped. If this
happens the gear box might be seriously damaged.
If for any reason is not possible to move the lever from “P” position although you are pressing the
brake pedal, through the safety grey button “sign (P)” on the steering wheel module is possible to
unlock the gear lever command.
“R” reverse mode:

It’s only possible to put on and take out the “R” (reverse) mode if the car is complete stopped and
brake pedal is pressed.
“N” neutral mode:

In “N” mode, it is possible to move the car pushing externally (pit lane use).
“D” automatic mode:

Not advisable for race. “D” mode is only advisable to move the car on the paddock zone. The
gear shifting is working in a low range of engine speed.
“S” automatic mode:




Pushing the gear lever backward one time when lever is in “D” the “S” mode will be engaged.
Driver display will shows now “S”. (left up corner)
Use “S” mode to drive in automatic shifting. Simultaneously is possible to use the steering
paddles.
It’s possible to use “S” mode in the launching system. The gear will shift up automatically. The
driver can pass to Tip mode in any moment.
It’s possible to pass from “D” or “S” to Tip and backwards always and in any moment.
“Tip” manual mode: “TS” (the most advisable for motorsport)




2.4
From the “S” gear lever position move the gear lever to the right side. Driver display will show
“TS” mode.
Use “TS” mode for drive in manual mode, handling the shifting by the steering paddles.
“TS” the shifting is manual. When the engine will reach rpm limit the power will limit (6800 rpm).
Downshift is protected preventing the engine rpm overriding. Shift demand will be active for one
second.
Car launching systems
There are two car launching systems for the standing starts, manual or automatic launch system.
“LCS” LAUNCH CONTROL SYSTEM -AUTOMATICLCS allows you to perform a semiautomatic car launching. This system is automatically activated if wheels
are absolutely stopped and brake pedal is pressed.
Launching time after brake signal pedal off:
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TECHNICAL MANUAL LEON CUP RACER
Process:
1.
2.
3.
4.
After the grid formation lap, stop completely the car on the grid line pushing the brake pedal.
Gear lever has to be in “S” or “TS” mode. If this mode was already in during formation lap, will
not be necessary move the gear lever.
Push foot throttle flat out. Engine will limit at ±4200 rpm.
Release the brake pedal and car will be launched. Driver has to control the wheel spin with the
gas pedal.
Summarizing: Arriving from the formation lap driving in “S” or “TS stops the car on the grid line
pressing the brake pedal. Push the foot throttle flat out (4200rpm) and release the brake when
you decide. (max time flat out 6 sec)
Control the wheel spin and enjoy.
Notes:




Starting in “S” is necessary to release a little bit the gas pedal from the full gas to disable the
launch system. After this, using the “S” mode, up shift is automatic.
Is possible to use the Launch Control System controlling the rpm. Advisable no bellow of 3500
rpm.
The system need brake press >10 bar. Push the brake pedal clearly.
With start lights in red: If you release just a little bit the brake pedal in any moment of the system
process will understand that launch is done and the clutch will load irreversibly.
MANUAL LAUCH SYSTEM
It’s possible to carry out a manu
al launching whit the same success.
Process:
1. After the grid formation lap, stops completely the car on the grid line.
2.
Push the brake pedal (Brake press >25 bar)
3.
Gear lever has to be in “S” or “TS” mode. If this mode was already in, it’s not necessary move
the gear lever.
4.
Release the brake pedal while you press down the gas pedal.
Notes:

2.5
It’s also possible to while you are braking put the engine in charge accelerating a little bit. Take
care the time you apply the engine charge because the clutch takes temperature very fast and
after a certain limit the clutch launch is coming slow. Recommendation not more than 3
seconds.
Speed limiter system
The speed limiter system allows limiting the car speed. This system is recommended for the pit lane area.
Speed limiter limitation is 60Km/h (tolerance - 2 km/h GPS speed)
Process:
1. Brake to reduce the car speed around 60 km/h or little less.
2. Release the brake and press the steering wheel red button as long as you want it acts.
3. Push the gas pedal fully. Car speed has to be limited.
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TECHNICAL MANUAL LEON CUP RACER
Notes:


2.6
th
Can be applied in different gears. Recommended 3rd or 4 gear.
Is not recommended to activate it in the track, when safety car or others.
Driver has to consider

Learn and memorize the steering wheel buttons place and functions will allow drivers a more fast
action and will help to not lose the track reference point.

Warm up the engine before starting. The minimum water temperature before to load the engine is
80⁰C.


Check the brake pedal is hard when car is standing and on the acceleration way.

Shift up the gear when shift light indicates. With 410 Nm 2WD front its recommend shift around
6300 rpm.

Shift down gears without stress. Automatic gearbox needs reduce engine rpm to permit the next
shifting down. Do not shift down 3 times consecutively if the previous gear was not engaged.
(memory active for 1 sec).


Last lap: Cool down brakes and engine water to avoid the engine and discs thermal shock.

If for any reason you have to drop out the car on the track put the gear lever in “N” Neutral to
save the transmission in case of being towed.
Warm up the tires before attacking. Without blankets use, the rear tires takes 2 laps to warm and
this car is very sensitive on that.
Display alarms: There are three different possibilities to show alarms, 1) LEDs lateral, 2) red
ribbon bellow screen 3) completely screen pop up message. Stops the engine if “pop up”
message appears. (Oil or water). Speaks with your engineer about the alarms configuration.
DISCS BEDDING PROCEDURE
To get the maximum life please follow the instructions below:
o
Where possible bed discs with used pads.
o
To reduce thermal shock during bedding the brake ducts may be 50% taped off.
o
Apply the brakes gently at low speed a few times to ensure correct installation.
o
Apply the brakes moderately, (progressively up to 50% race speed, 25% race pressure), for 1020 applications to ensure above 80% pad face contact with disc. (The contact with the disc face is
particularly important at the inner swept area. The first time a driver gets used to bedding discs on
a car it is worthwhile getting him to return to the pits to check contact is sufficient before
preceding to the next step).
o
Progressively build up to about 70% of race speed and 50% of race pressure, then apply brakes
for approximately 25 applications.
o
Perform one lap cooling down before returning to the pits.
o
The orange temperature paint should be turned on the surface and the green 75% of the way
through the disc thickness at which point any tape can be removed. On returning to the track
progressively come up to race speed and pressure.
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TECHNICAL MANUAL LEON CUP RACER
3
DISPLAY & FUSE BOX
MXG is the new AiM dash-logger designed to acquire and display data coming from your ECU, the internal
accelerometer and gyro, as well as from the GPS module, analog/digital inputs and predefined math
channels.
Performance and data acquired can also be incremented adding expansion
modules.
It’s possible to scroll the pages through the steering wheel module black button (7).
To enable “the lap time” is necessary to insert the track where you are running.
Track load has to be done by the program GPS Manager available at the sw
RaceStudio3.
SmartyCam: The on-board cameras that overlays on videos the data sampled by your logger.
Software RaceStudio3, Firmware MXG and documentation available on the AIM web site:
http://www.aim-sportline.com/eng/download/index.htm
Display logger user guide available on the AIM web site:
http://www.aim-sportline.com/download/doc/eng/mxs-mxg/MXG_user_guide_101.pdf
3.1
Display alarms and shift lights
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TECHNICAL MANUAL LEON CUP RACER
Eight configurable RGB alarm LEDs, combined with lower red bar alarm and Red Pop Up alarm.
Select solid alarm or flashing one – and the flashing frequency, choose to have an accompanying text
message and set the alarm priorities.
Alarms and shift lights
IMPORTANT: the change of the alarms or shift lights is under user responsibility.
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TECHNICAL MANUAL LEON CUP RACER
3.2
Data acquisition analysis
MXG logger data acquisition channels information:
CHANNEL
NAME
P_turbo
DATA ACQ NAME
UNIT
SCALE
P_TURBO
Pressure (bar)
1...2.21
T_air
T_ENG_AIR
Temperature (°C)
T_oil
T_ENG_OIL
Temperature (°C)
T_water
T_ENG_WATER
Temperature (°C)
T_extern
T_AIR
Temperature (°C)
RPM
RPM_ENG
rpm
Brake
FLAG_BRAKE
on/off
ANA1
P_BRK_FRONT
Pressure (bar)
0…140
ANA2
P_BRK_REAR
Pressure (bar)
0…140
ANA5
P_ENG_OIL
Pressure (bar)
1.5… 4
ANA6
P_ENG_FUEL
Pressure (bar)
2… 7
ANA7
FUEL_LEVEL
Amount (litres)
0… 55
Pedal
POS_PEDAL
Load (%)
0…100
Gear_Lever
POS_GBX_LEVER
number
DSG Mode
POS_GBX
number
Gear
GEAR
number
Tip Down
TIP_DOWN
sign
0=Init, 5=D, 6=N, 7=R, 8=P, 10=Tip+,
11=Tip-,
12=S, 14=Tip Pos., 15=Failure
0=Init, 5=P, 6=R, 7=N, 8=D, 9=S, 13=TD,
14=TS, 15=Failure
0=N, 1=1ª, 2=2º, 3=3º, 4=4º, 5=5º, 6=6º,
9=P, 10=S, 11=D/E, 12=Intermediate,
13=Rev, 14=undefined, 15=failure
1=Tip Down
Tip Up
TIP_UP
sign
1=Tip Up
Diff Map
POS_DIF_MAP
number
1-2-3
Gearbox temp.
T_GBX_OIL
Temperature (°C)
10…138
Y_Acc
G_CH_Y
acceleration (g)
-1,27…1,27g
X_Acc
G_CH_X
acceleration (g)
-1,27…1,27g
YawRate
W_CH
Angular speed (°/s
Speed_RL
V_WHL_RL
Velocity (kph)
0…250
Speed_RR
V_WHL_RR
Velocity (kph)
0…250
Speed_FL
V_WHL_FL
Velocity (kph)
0…250
Speed_FR
V_WHL_FR
Velocity (kph)
0…250
Steering Angle
A_STE
Angle (°)
0…800°
FuseState5
FLAG_FBX_F5
number
0… 8
FuseState4
FLAG_FBX_F4
number
0… 8
FuseState3
FLAG_FBX_F3
number
0… 8
FuseState2
FLAG_FBX_F2
number
0… 8
FuseState1
FLAG_FBX_F1
number
0…8
Battery
Voltage
mV
760…6800
0 / 1 (1= braking)
0..163,82 Rad/s
0 – 14.700 mV
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TECHNICAL MANUAL LEON CUP RACER
Form AIM “GPS”
Unit
GPS_Speed
kph
GPS_Nsat
**
GPS_LatACC
g
GPS_LonACC
g
GPS_Slope
deg
GPS_Heading
deg
GPS_Gyro
deg/s
GPS_Altitude
m
Nº of satellites on
Following, there are shown the standard approximate values at 20°C air temperature.
Channel measures
Idle speed
Std use values at Tair 20°C
Maximum value
P_TURBO
1 bar
2.35 bar **
P_ENG_FUEL
4.8 bar
5.8 bar
7 bar
P_ENG_OIL
1.5 bar
4 bar
5 bar
T_ENG_AIR
<
42°C
>75°C
T_ENG_OIL
<
122°C
>147°C
T_ENG_WATER
<
95°C
>120°C
T_GBX_OIL
<
114°C
>138°C
>2.36bar
Notes:
 The “maximum value” underlined in orange shows the value before performance restrictions or
protection.
 ** boost. The boost pressure has not changed between cars 2014 and 2015. The diagnosis value
showd in cars 2014 was limited at 2.2. Cars 2015 will show the direct value.
3.3
MXG channel expansion scheme
MXG logger data expansion channels:
Scheme 1: Data logger standard connection scheme (car delivery).
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TECHNICAL MANUAL LEON CUP RACER
Scheme 2: Data logger connection scheme with Smarty cam and expansion module.
Features
BEACON
Circuit config.
Extra sensors*
Notes:



Remarks
The MXG system use Only GPS signal.
 Through the “RaceStudio3” with/or “Track Manager” programs it’s possible
to activate all circuits in the world.
 There is possible to create your own circuit with the program.
 In case you want to add extra sensors, you have to connect them to an
“Expansion module” as shown in the scheme “2”
 Any extra sensor have to be connected through the AIM DATA HUB +
CHANNEL EXPANSION (scheme 2),
For the SEAT Leon Eurocup participants: Any extra sensor have to be connected through AIM
system
Channel expansion module and sensors only available through AIM dealers.
IMPORTANT: If for any reason it’s necessary to send data acquisition files to SSp, you have to
send the forth data files extensions: .drk, .bak, .gpk,.rrk, .xrk
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TECHNICAL MANUAL LEON CUP RACER
3.4
Fusebox
Fuse box LED lable
The Leon Cup Racer fusebox it’s an electronic box that control the power supply
to practically all devices. Internally the fuses are resettable automatically, so
never is necessary to change a fuse. In case of malfunction has to be send to
SEAT Sport.
Through the fuse box there is also possible to check the fuses activation, so you
will know if the current or signal was sent.
To check the proper functioning exists three ways:
o
Through the RaceStudio3 in live view
o
Through the RaceAnalisis channel analysis
o
With the red LEDs on the fuse box.
In case to find a malfunction it’s necessary to control the corresponding wiring or
device.
On the following table is shown the fuse analysis information:

Channel name: There are 5 channels for analysis

Bite number: Each flag channel controls 8 fuses.

Data value: Is the value you can check on the data acquisition.
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TECHNICAL MANUAL LEON CUP RACER
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TECHNICAL MANUAL LEON CUP RACER
Example: In the acquisition screenshot bellow, it’s shown the channel “flag_FBX_1” in green the
value is “7” when braking and 0 when no braking. On this case the information is that there is a
problem on the brake light line.
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TECHNICAL MANUAL LEON CUP RACER
3.5
Auxiliary connectors
The main car wiring loom is prepared with some auxiliary connector to make easy the auxiliary devices
connections.
RADIO AND DRINK:
Behind the driver seat there are two free connectors in association with the steering wheel module, (Radio
and drink). Connect here your radio and your drink system and through the steering wheel module can
manage both.
Radio connector
Main loom reference connector:
4D0 972 704
Matching connector:
1J0 972 714
Pin out
Terminal
1
+30 up to 8A
FS 2,8 x 0,8 (*)
2
GND
FS 2,8 x 0,8 (*)
3
PTT
FS 2,8 x 0,8 (*)
4
PTT
FS 2,8 x 0,8 (*)
Drink connector
1
2
Matching connector:
Pin out
up to 2.5A
GND
1J0 973 822
Terminal
FUEL CONSUMPTION DISPLAY AND TCR SCRUTINEERIG EVO4 LOGGER:
This connector is placed in the driver cockpit above the central tunnel (front). Also cold be used for other
requirement.
Auxiliary power supply
Matching connector:
191 972 733
1
2
3
Pin out
+30 up to 3A
GND
CAN H traction
Terminal
FS 2,8 x 0,8 (*)
FS 2,8 x 0,8 (*)
FS 2,8 x 0,8 (*)
4
CAN L traction
FS 2,8 x 0,8 (*)
5
CAN H chassis
FS 2,8 x 0,8 (*)
6
CAN L chassis
FS 2,8 x 0,8 (*)
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TECHNICAL MANUAL LEON CUP RACER
Transponder: This auxiliary connector it is placed beside to the right front headlight.


All SEAT Leon Cup cars bought to participate on the SEAT Leon Eurocup will be provided
with the transponder mounted.
The cars bought for other championships will be provided without transponder.
SEAT EUROCUP TRASPONDER
Transponder
Availability
Type
Energy
Position
Remarks
All Eurocup participants have installed // rest:
purchase order
Radio frequency
Connected to the car 12v (with fuse)
See drawing // right side // body shell support
ready.
Transponder
Matching connector:
357 972 762
1
2
Pin out
12v
GND
Terminal
FS 2,8 x 0,8 (*)
FS 2,8 x 0,8 (*)
Transponder for SEAT Leon Eurocup.
Auxiliary service connectors: Auxiliary free.
They are placed on the cockpit bay, in the middle of the tunnel.
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TECHNICAL MANUAL LEON CUP RACER
Nº1, auxiliary power supply: (+15. +30. GND x2). (see picture, part nº1)
Additional power supply
Main loom reference connector:
Matching connector:
1
2
3
4
4D0 972 704
1J0 972 714
Pin out
Terminal
+30 up to 8A
+15 up to 5A
GND
GND
FS 2,8 x 0,8 (*)
FS 2,8 x 0,8 (*)
FS 2,8 x 0,8 (*)
FS 2,8 x 0,8 (*)
Nº2, auxiliary analogic sensor: Connected to the dash logger. 2 connectors available, (see picture)
Auxiliary power supply
Matching connector:
1
2
3
Pin out
5v
signal
GND
191 972 713
Terminal
FS 2,8 x 0,8 (*)
FS 2,8 x 0,8 (*)
FS 2,8 x 0,8 (*)
Power supply cut:
There is a connector that active the power supply to the
fuse box, so in case of disconnection cuts all devises power
supply.
You can unplug it in case of transport or a most safety
disconnection in case of workshop big jobs.
See connector place close to the fuse box main connectors
on the picture beside.
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TECHNICAL MANUAL LEON CUP RACER
4
4.1
SETTING ADJUSTMENTS
Delivery car set-up
Due the production issues, small changes on this set up sheet can be done. Do your own check.
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TECHNICAL MANUAL LEON CUP RACER
Front and Rear set up ride height measurement points:
4.2
Steering rack centering
The steering rack is electric and steering angle sensor has to be electronically aligned with the wheels on
the main time.
How to proceed align the steering angle sensor:
It is necessary fix the steering wheel. To do it, you can use straps fixed on the top of the roll cage or
other kind of std. tools. The most useful is two straps going through the steering wheel and the roll cage.
The use of a rack centring stopper tool is not recommended because is difficult to get the steering angle
sensor at “0 deg”. The most important is to obtain the toe alignment with the sensor at “0 deg”.
Proceed as following:





Switch on main and ignition switches.
Turn left and right to get the steer angle signal.
Fix the steering wheel with straps when the steer angle
is “0 deg”
Switch off the ignition and main.
You can now preceed to the alignment jobs.
With this process the steering angle signal will be at 0 deg, with the wheels aligned. This fact is
very important for the steering assistance and for the electronic slip differential behaviour.
4.3
Suspension adjustments
Wheel ratio
Damper travel
Front
1mm wheel / 0,9mm damper
115mm
Rear
1:1
118mm
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TECHNICAL MANUAL LEON CUP RACER
4.4
Front Camber and Toe adjustment
How to proceed to adjust camber and toe.
The front suspension is very special on this car due the kinematic characteristics. To reach the front
suspension set up value is recommended to proceed as following:
1.
2.
3.
4.
Car ride height. Put the ride height at your choice trough spring adjustment.
Camber. To change the camber is recommended to change through moving the steering rack
arm first. The camber will change quickly.
Toe. To change the toe enlarge or reduce the wishbone adjustment.
Check and adjust a second time if necessary
Although this process information seams estrange, is the best and fast way to obtain the
camber and toe adjustment.
Front Wishbone adjustment:
Underneath of the front wishbone there is a bolt to control the
adjustment movement. Unblock the four screws that are fixing
the camber regulator plate and proceed at the camber
adjustment.
After any intervention, fix the wishbone regulator plate bolts
in the right tighten.
Maintain the wishbone regulation plate clean and little oiled
between plates.
Front regulation table. (the values shown are approximate)
4.5
Camber
Toe regulation
-6
-5,5
-5
-4,5
-4
-3,5
3
10,5 Turns
7 Turns
3,5 Turns
0
-3,5 Turns
-6,5 Turns
-10 Turns
Wishbone regulation
1,5 turns = 10’ camber
13 Turns
8,3 Turns
4,5 Turns
0
-4 Turns
-8 Turns
-12,5 Turns
Rear Camber and Toe adjustment
How to proceed to adjust camber and toe.
1.
2.
3.
4.
Car ride height. Put the ride height at your choice trough
springs adjustment.
Camber. To change the camber is recommended to
change through moving the “boomerang” arm.
Toe. To change the toe enlarge or reduce the rear arm.
Check and adjust a second time if necessary
The rear Camber regulation does not have relation with
the toe movement, so you can change rear camber without any toe movement.
After the camber adjustment job, check that the uniball is placed in the middle of its housing.
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TECHNICAL MANUAL LEON CUP RACER
Rear Camber value vs rear camber regulation screw turn.
Camber
-2
-2,5
-3
-3,5
-4
-4,5
-5
Camber arm regulation
1,5 Turns
1 Turns
0,5 Turns
0
-0,5 Turns
-1 Turns
-1,5 Turns
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TECHNICAL MANUAL LEON CUP RACER
4.6
Dampers
Front Damper information
STTV technology (Single Tube Twin Valve)
2 – way adjustable in bump and rebound
Aluminium outer housing
Upside down cartridge
Notes:


Start to count the clicks from close (+) to open.
Be careful, do not squeeze to close strong the last click.
Rear Damper information
The rear damper is equipped with a 1-Way parallel adjuster.
Each click adjusts the bump and rebound characteristics parallel.
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TECHNICAL MANUAL LEON CUP RACER
Notes:


Starts to count the clicks from close (+) to open.
Be careful, do not squeeze to close strong the last click.
Characteristics and adjustment range of the front and rear struts:
FRONT
REAR
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TECHNICAL MANUAL LEON CUP RACER
The available springs for front and rear struts are the following:
Measures
160-60-120
160-60-110 (car delivery - front)
160-60-100
160-60-90 (car delivery - rear)
160-60-80
160-60-70
Nm
120
110
100
90
80
70
Remark
Front use recommended
Front use recommended
Front use recommended
Rear use recommended
Rear use recommended
Rear use recommended
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TECHNICAL MANUAL LEON CUP RACER
4.7
Antiroll bars
Two front anti roll bar available: 22x2 and 22x3. Car delivery: 22x3.
FRONT ARB
OD (mm)
Thickness (mm)
Hard (Nm/ºChassis)
Mid (Nm/ºChassis)
Soft (Nm/ºChassis)
22
2,0
Chassis Roll Stiffness from ARB
1548
991
688
22
3,0
2021
1293
898
Two rear anti roll bar available: 22x3 and 22x4. Car delivery: 22x3.
REAR ARB
OD (mm)
Thickness (mm)
Hard (Nm/ºChassis)
Mid (Nm/ºChassis)
Soft (Nm/ºChassis)
4.8
22
3,0
Chassis Roll Stiffness from ARB
1252
1061
898
22
4,0
1454
1232
1043
Kinematics
FRONT
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TECHNICAL MANUAL LEON CUP RACER
REAR
4.9
Brakes
Available brake pumps range.
MASTER CILINDER
AP 15 MM
AP 15.9 MM
AP 16.8 MM
AP 17.8 MM
AP 19,1 MM
AP 20,6 MM
AP 22,2 MM
AP 23,8 MM
Push Rod
PRT 110
PRT 110
PRT 110
PRT 110
PRT 110
PRT 110
PRT 110
PRT 110
Remarks
SEAT Sport car delivery
SEAT Sport car delivery

It’s not advisable to use more than two pump diameters between front and rear.

On the dashboard screen it’s shown the front / rear pressure and the balance percentage. The
recommended percentage is 60% front. (car delivery)

Brake balance channel:
P_BRK_FRONT
P_BRK_FRONT + P_BRK_REAR
× 100
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TECHNICAL MANUAL LEON CUP RACER
4.10
Aero
All aerodynamic parts have to be in good conditions. Check periodically the fixations.
Rear wing:
 The rear wing has extensive regulation. Zero is a standard setting for the car.
 Wing angle – 5° has considerable influence on the rear down force.
 Wing angle – 10º has big influence on the rear down force as well as speed.
 Lateral plates are individually adjustable. (2015 lateral plates)
Front splitter:
 Check periodically the fixations. Have to be in good conditions.
 Check the front splitter angle that has to be at 0º when pitch is 0º.
Pitch:

Measure the pitch angle on the body shell over the door sill.
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TECHNICAL MANUAL LEON CUP RACER
5
5.1
WORKSHOP MANINTENANCE
FIRST ROLLOUT
SEAT Sport checks all cars in a rollout before customer delivery. This rollout consist in 5 laps in a circuit,
reaches high speed in a long straight and check the launch control in a standing start. After the rollout the
SEAT Sport engineers check the data acquisition and all car functions.
IMPORTANT: Although the SEAT Sport is doing a rollout check is strongly recommended to carry
out a suspension check before first’s customer rollout and after the first free practice.
(sub-frame, power train, engine brackets, etc, fixations.)
5.2
Check list
After any rebuild or main job is recommend to carry out a check list. It’s possible do it with a lap top with
RaceStudio3 program or direcly to the car display.
ENGINE
BRAKE
FUNCTIONS
Oil level
Water
Brake fluid
CHECK LIST with ENGINE STOPED
On the dipstick mark / Toil > 70⁰C
On the bottle mark
On the bottle mark
CHECK STEERING WHEEL FUNTIONS
OK
OK
Rain Lights
Driver Fan
Page Change
Safety Brake Signal
Diff Map Change
Windscreen Water
Wiper
High Beam
AIM on-line
conditions
CHECK LIST with ENGINE IN IDLE SPEED
ENGINE
Water Temp
87ºC / 92ºC (thermostat cicle)
Fan
Active at 92ºC
P oil (WT<25ºC)
4 bar
P oil (WT>25ºC)
2,5 bar
P fuel low
> 4,1 bar
Alternator
> 13,5 volts
Boost Press
0,3 bar @ 2500rpm
Speed limiter
Gear 4 @ 60km/h
Tipp TS
Changing gears / check SWM signal -- +
GEARBOX
Value
OK
Nº gear display
DIFF
FUSEBOX
Activar Pump
FLAG_FBX_1
FLAG_FBX_2
FLAG_FBX_3
FLAG_FBX_4
FLAG_FBX_5
0
0
0
0
0
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TECHNICAL MANUAL LEON CUP RACER
5.3
Vehicle & parts identification
V.I.N. (Vehicle Identification Number) is welded on the roll cage
Nº: VSSMK35F4ESSPxxxx
Engine identifications.
Nº: CJX xxxxxxx
Gear box identification.
Nº: C0xx
General ENGINE seals view:
view
Distribution seal
detail
Turbo seal detail
Slip differential identification
Nº D0xx
General GEARBOX – DIFF seals
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TECHNICAL MANUAL LEON CUP RACER
5.3
Fluids information
Fluids
Engine
From
Gear box
VW-Audi
Remarks
CASTROL EDGE 5W-30
VN0000053000
_G052182A2
Electronic Slip
Differential
Drive shaft
Coolant
VW
_G060175A2
VW-Audi
VN0000040401
VN0000060400
Brake fluid
Fuel
Windscreen cleaner
PANTA (Eurocup
SEAT)
Free
CASTROL SRF
VN0000062400
NS 102 Ron
Quantity
Substitution with filter
change 5,7 lts
Substitution 5,2 lts
Mechatronic 3 – 4 lts
Unit
0,7 lts
Substitution 0,5 lts
100 gr
5 lts
—
0…..2 lts
Notes:





SEAT Leon Cup Racer: Use only the fuel distributed on the race track.
It’s forbidden any product addition on the fuel.
Fuel: standard fuel 98 oct. from petrol stations to 102oct.
Is recommended not to mixt fuels, could contaminate one from the other.
Gearbox and Slip differential are supplied with the right level. It’s not necessary any level control
if there aren’t leakages.
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TECHNICAL MANUAL LEON CUP RACER
5.4
Engine service
Control routine before start to run:




Check the oil level: With the oil temperature up to 70°C, stop the engine and wait 2 minutes, then
you can check the oil dipstick. The oil level must be at the top of the marked zone on the dipstick.
Check the water level before start.
With the engine running, check there isn’t any oil, water or fuel leakage.
Check the fan functionality. Operating range 92°C to 87°C.
Maintenance routine:








Change the engine oil and oil filter at the indicated mileage.
Engine spare parts must be from VW group or SEAT Soport original parts, detailed on the Leon
Cup Racer parts catalogue.
Use always fluids detailed on the Leon Cup Racer parts catalogue.
Clean and check the air filter in each event. At the urban circuits is recommended clean or
replace more frequently. It’s also recommended to have two or three air filters and replace during
the weekend. Change is strongly recommended in case of rain.
Check that the alternator belt is clean and there aren’t small stones inside the Poly-V.
Often clean the radiator and intercooler panel.
If any doubt, contact to the SEAT Sport service.
Check the SEAT Sport seal is in good condition.
Parts subject to frequent service:
Engine
Oil drain plug
Oil filter plastic cover
Oil filter
Spark plug
Torque
By hand
50 Nm
<<
2,8 Nm
Remarks
Change the plastic cap
Moisten the “O” ring
Use original VW parts
For a detailed parts substitution information download yourself the “Workshop Manual” from our web,
“www.seat-sport.com”.
5.5
Air filter
Air filter
Air filter substitution
Air filter clean
Torque
By hand
Remarks
4 small bolts over plastic. Be careful.
1) Clean the cotton air filter following the procedure
showed.
2) DO NOT use compressed air or high-pressure air
to clean.
Use only the recommended oil for cotton filters.
Notes:



The air filter type and measurements are identified on the
“Technical Regulations”. It’s not allowed any modification or
change.
The air filter clean and properly oiled is critical for the turbo
charger life. It is strongly recommended to follow the cleaning
procedure as well as the timing.
After using in rain conditions is recommended the cleaning or
replacement.
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Air filter std. clean procedure
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TECHNICAL MANUAL LEON CUP RACER
5.6
Gearbox & Slip differential service
Control routine before start:



Check that there isn’t any oil leakage.
Operating range 70°C to 135°C.
Do not load the engine until the gear box temperature its upper to 70°C. (Control on the display
screen).
Routine maintenance:




Change the gear box oil and filter in the indicated mileage. (see mileage table)
Oil filter, as well as the rest of the gear box spare parts must be from VW group or SEAT Soport
original parts, detailed on the Leon Cup Racer parts catalogue.
If there isn’t any oil leakage there is not necessary any level control. (paragraph 6)
Check the SEAT Sport seal is in good condition.
For more detailed maintenance or parts substitution information download yourself the “workshop manual”
from our web, “www.seat-sport.com”.
5.7
FDX - Slip differential control & service
Routine maintenance:



Change the FDX oil in the indicated mileage. (See mileage table). Use only the recommended oil.
If there isn’t any oil leakage there is not necessary any level control.
Send to SEAT Sport for revision when recommended service mileage is reached.
Slip differential jobs
FDX oil level check cap
Torque
15 Nm
a) FDX view –level cap and seal–
Remarks
Change every time
b) FDX level cap –bottom view–
How to change the FDX oil:
To replace the oil is recommended to disassemble the unit from the car.
Open the cap bellow and drain it and close it again. Measure the quantity and put in the same quantity.
If you are doing it mounted on the car, take care, 100 ml will not be possible to add from the cap (shown in
the picter “b” above). The last 100ml have to be add trough the venting pipe on top.
Notes:
 In case of disassembling the unit from the car, the unit must be positioned in vertical position, as
it is shown in the picture, to avoid any oil leakage.
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TECHNICAL MANUAL LEON CUP RACER
5.8
Fuel
The fuel tank is coming from series, using the standard flow fuel pump and additionally there is a second
flow pump on the opposite side.
Standard Fuel tank features
Fuel tank type
Capacity
Minimum fuel level before engine fault
Additional fuel tank features
Standard fuel tank from Quattro version
55 lts Standard tank / *option 60 lt additional fuel tank (LR
version)
> 8 lts. (in long corners with high lateral forces)
FT3 FIA Homologated
60 lt additional fuel tank // possible to reduce the capacity
by adding balls.
This additional fuel tank don’t have fuel pump. It supplies
the main tank by gravity.
Notes:


The Quattro version fuel tank allows use a straight exhaust system, decreasing the fuel
temperature due to the exhaust irradiation. Check periodically all tank protections are in good
conditions.
After a crash or out of track driving check the inner flow fuel pumps fixations.
Fuel tank drain:
Hydraulic: There is a FIA fast fuel coupling placed on the engine bay. The contra connector is
available on the parts catalogue.
Electric: The car wiring loom is ready to connect an external interface wiring in order to activate the
main fuel pump directly.
How to proceed:

For the fuel tank pump activation is necessary to connect the SSp tool between the fuel
pump wiring connector, placed on the right rear door and beside to the auxiliary power
supply. Unplug the car connector and plug the SSp tool connector.

Connect the front hydraulic pipe to FIA fast coupling.

Connect now the tool to the main supply auxiliary connector and push the tool switch.
For safety, it is strongly recommended to carry out the process with the main switch off.
Fast fuel coupling for drain (FIA homologated)
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TECHNICAL MANUAL LEON CUP RACER
Note:





5.9
IMPORTNT: Take care, don’t damage the fuel pump during the drain process. Do not maintain
the pump activated without fuel. Stop the drain when appears air bubbles.
IMPORTANT: The drain tool connects directly to the battery. DO NOT ACTIVATE THE TOOL
SWITCH WITH THE CAR MAIN SWITCH ON.
On the Leon Cup Racer parts catalogue it is available the extraction kit.
To carry out this procedure is also possible to connect the extraction tool to an auxiliary battery
help.
The Leon Cup Racer body shell is ready to add an additional fuel tank. This tank would be
connected in line with the first one and supplies the fuel to it.
Electronic modules
The car has installed the following modules:
Electronic MODULES
ECU
Mechatronic
Electronic slip differential
Low fuel pump control
Electronic Steering rack
ESP unit
Gateway
Black box
MXG display / logger
Fuse box
Driver module
Transponder
Remarks
Continental /Symos 18.1
VW
BorgWarner
PWM control module
VW
Continental (not hydraulic connexion
for cup cars)
VW
Audi
AIM
SEAT Sport
SEAT Sport
XXX
Place
Engine bay
Inside gear box
FDX (external)
Fuel tank (external)
Front subframe
Cockpit
Cockpit
Cockpit
Cockpit
Cockpit
Cockpit
Engine bay
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TECHNICAL MANUAL LEON CUP RACER
5.10
Airjack
The SEAT Cup Racer car is using the Kronteck
http://www.krontec.de/katalog_e/start.htm
Air lance:
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TECHNICAL MANUAL LEON CUP RACER
6
PARTS MILEAGE
ENGINE
Inspection
Engine
Spark plug
Service
Change
Remark
8.000
12.000
2.000
Serviced by SEAT Sport
Use original parts only
1.000
Use recommended oil only
1.000
season
Use original parts only
2 units rolling change adv.
Engine oil
Oil filter
Cotton air filter
Once x event
Poly-V belt
Once x event
TRANSMISSION
Inspection
Gear box
Oil gear box
Once x event
2.000
Service / km
Change
Remark
8.000
12.000
5.000
Serviced by SEAT Sport
Use original parts only
Gbx oil filter
5.000
FDX (slip differential)
FDX pump
Oil FDX
Drive shaft
Once x event
FRONT AXLE
Inspection
Front dampers
Ball joints
Steering rod inner
joint
Steering rack
Wheel hub
Front Discs
8.000
Serviced by SEAT Sport
Replace at this mileage
Use recommended oil only
5.000
12.000
4.000
5.000
10.000
Service / km
Change
Remark
5.000 / 1 year
Once x event
8000
5.000
Seat Sport service
Always check tolerance
Once x event
5.000
Always check tolerance
Once x event
Once x event
15.000
10.000
1.500
Change when noise
Change when cracks
Disc bells
5.000
Brake balance bar
Once x event
4.000
REAR AXLE
inspection
Service / km
Change
Remark
Rear dampers
Ball joints
5.000 / 1 year
Once x event
8.000
5.000
Seat Sport service
Always check tolerance
Wheel hub
Once x event
10.000
Change when noise
Rear Discs (solid)
Wheel nuts
1.500
3.000
SECURITY PARTS
Service / km
Extinguisher
5 years
Backet
Safety Belts
Change
Remark
Service in SSp or OMP
5 years
5 years
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TECHNICAL MANUAL LEON CUP RACER
7
SAFETY
SAFETY
Remarks
AIR JACK
3 Air Jacks on the car
Max press 30 bar
Images
Safety:
Safety Props: For any job under the car
Use ALWAYS the air jack Safety Props.
(x3)
EXTINGUISHER
Material: Aluminium
Weight: 6.2 kg
Activation: Electric
Use: Cockpit and engine bay
Safety:
Cheek the inner press bottle. Have to be
in the green area.
Fire extinguisher system: Check always
that the 9v inner battery is in good
conditions.
Do not forget to put the toggle in “on”
when car is running.
BACKET
FIA Homologated 8855 – 1999
Gel coated fiberglass shell
W side fixing points
HANS Compatible
Safety:
Check the homologation label “expiry
date” period.
Check ALWAYS the fixations
Change if big crash.
SAFETY BELT
Safety:
Check always the fixations are well fixed
Check the homologation label “expiry
date” period…
Check always the driver is strongly fixed.
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