LEON CUP RACER - SEATMotorsportItalia

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LEON CUP RACER2015TECHNICAL MANUAL

TECHNICAL MANUAL LEON CUP RACER1 de 48

TECHNICAL MANUAL LEON CUP RACERTable of contents1234TECHNICAL INFORMATION . 41.1Leon Cup Racer Display. 41.2Dimensions and weights. 51.3Body shell . 61.4Powertrain . 71.5Rim & Tire . 91.6Electronic units . 9DRIVERS CONTROL . 112.1Main console . 112.2Steering wheel module . 112.3Gear lever functions . 122.4Car launching systems . 132.5Speed limiter system . 142.6Driver has to consider . 15DISPLAY & FUSE BOX . 163.1Display alarms and shift lights . 163.2Data acquisition analysis . 183.3MXG channel expansion scheme . 193.4Fusebox . 213.5Auxiliary connectors . 24SETTING ADJUSTMENTS . 274.1Delivery car set-up. 274.2Steering rack centering . 284.3Suspension adjustments . 284.4Front Camber and Toe adjustment . 294.5Rear Camber and Toe adjustment . 294.6Dampers . 314.7Antiroll bars . 344.8Kinematics . 344.9Brakes . 362 de 48

TECHNICAL MANUAL LEON CUP RACER4.105Aero . 37WORKSHOP MANINTENANCE . 385.1FIRST ROLLOUT . 385.2Check list . 385.3Vehicle & parts identification . 395.3Fluids information . 405.4Engine service. 415.5Air filter . 415.6Gearbox & Slip differential service . 435.7FDX - Slip differential control & service. 435.8Fuel . 445.9Electronic modules . 455.10Airjack . 466PARTS MILEAGE. 477SAFETY . 483 de 48

TECHNICAL MANUAL LEON CUP RACER1TECHNICAL INFORMATION1.1Leon Cup Racer DisplayEngine\ 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 systemTurbocharged; 4-cylinder in lineDirect fuel injection1984 cc82,5 x 92,8330 PS410NmContinental SIMOSRacing catalysed 104dB55 lts Standard tank with additionalactive 60km/hactiveTransmission\ Transmission\ Gearbox\ Differential\ Clutch\ Shift controlFront-wheel-drive6 speed DSGVAQ ellectronically managedMulti disc oil cooledElectronic on steering wheelChassis and Suspension\ Front suspension\ Anti-roll bar\ Rear suspension\ Front brakes\ Rear brakes\ Brake pedal\ Steering system\ Rims\ ABSBody and aerodynamics\ Roll bar Driver position\ Weight\ Front Width (max)\ Rear Width (max)\ Length\ Wheel baseCar check-control\ Acquisition system\ Car check-control\ AirjackMcPherson, adjustable in height, toe and camberFront and rear adjustableMulti-link axel, adjustable in height, toe andcamber6-piston callipers, 362 mm steel ventilated discs272 mm steel discsUnitary with brake balance regulationFull Ellectrical power steering rackRemovedFIA Homologated and Hans adapted1.120 kg1.950 mm1.950 mm4.363 mm2.666 mmAIM - MXG 28 channels 8 analogicsAuto-diagnosis OBDII / DiagRA - LEComplete car kit4 de 48

TECHNICAL MANUAL LEON CUP RACER1.2Dimensions and weightsDimensionsOverall lengthOverall bodywork front widthOverall bodywork rear widthWheel baseOver hang front splitterOver hang front bumperOver hang rearOver hang rear wingMinimum ground clearance4382 mm1950 mm1950 mm2665 mm897 mm868 mm820 mm165 mmfreeWeight:Total weight in race conditions without fuelCar balanceDistribution weight/powerMeasured on the mud-ward at the front axleMeasured on the mud-ward at the rear axleFrom the wing vertical to the bumper70 mm is the performance recommendation1150 Kg (1)63,2% front 36,8% rear3,48 Kg/cvNote:(1) This value means the minimum weight on the “Technical Regulations” in race conditions.5 de 48

TECHNICAL MANUAL LEON CUP RACER1.3Body shellPART NUMBER0102030405111213141516 (2014)16 (2015)1718192122232425DESCRIPTIONBONNETLEFT / RIGHT FRONT BONNETLEFT RIGHT REAR BONNETROOFLUGGAGE COMPARTMENT COVERBONNET OPPENINGFRONT SPLITTERFENDER AIR EXITFRONT BUMPERREAT BUMPERLEFT /RIGHT SILL TRIM PANELLEFT /RIGHT SILL TRIM PANELLEFT / RIGHT REAR DOOR EXTENSIONLEFT/RIGHTREARFENDEREXTENSIONLEFT / RIGHT FRONT NCARBONFIBER GLASSFIBER GLASSPLASTICFIBER GLASSCARBON (painted)WINSCREENLEFT / RIGHT FRONT DOOR WINDOWLEFT / RIGHT REAR DOOR WINDOWLEFT / RIGHT REAR TRIANGLEWINDOWREAR WINDOWGLASSGLASSGLASSCARBON (painted)CARBON (painted)PLASTICPLASTIC6 de 48

TECHNICAL MANUAL LEON CUP RACER1.4PowertrainEngineENGINE FEATURESTypeEngine identificationCylinder capacityCorrected cylinder capacityMaximum powerMaximum torque (Nm/ rpm)Max rpmSpecific PowerElectronic control unitFuelFuel ConsumptionExhaust / dBDistributionOil systemWater pumpWater thermostatFan rangeStandard Fuel tank featuresFuel tank typeCapacityMinimum fuel level before enginefault2,0 TSI / Turbocharged & direct injectionCJX1984 cc1984 x 1,7 3372,8242 KW (330 Hp) at 6250rpm410 Nm at 4600 rpm6800 rpm165 CV/lCONTINENTAL SIMOS 18.1RON MIN 98 , RON MAX 1020,37 to 0,42 l/kmRacing Catalyst FIA Homologated / 104 dBChain (sealed)Wet sumpOne electric water pump two auxiliary pumpsDouble electronic thermostatOperating range 92 C to 87 CStandard fuel tank from Quattro version55 lts Standard tank 5 lts.Engine power and torque curve:7 de 48

TECHNICAL MANUAL LEON CUP RACERGear box & Slip diff.Gear box featuresTransmissionGear boxDifferentialDifferential settingsMAP 1MAP 2MAP 3ClutchGear box mode commandGear shiftGbx. Electronic Control UnitCooling systemLaunch control systemDown shift over rev protectionFront wheel drive6 speed DSG (semi automatic gbx)VAQ Electronic slip differential3 Map available.Map swapping through the steering wheel module green button.Base mode, No OverSlip, Only yaw damping in speeds above110km/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 brakingRecommended use when medium grip. (used tyres)Prelock dependent from engine torque, 200 Nm prelock duringbraking(releasing earlier than 2)Recommended use when grip is low or rainDouble multidisc clutch in oil bathElectronic on the central gear leverPaddles on the steering wheelIntegrated mechatronic in oil bathExchanger oil - waterActivatedActivated / 1sec memoryGear box RatiosGROUP 1-23-4GROUP 5-615720,2088318018920720,278RPM1GEARSHIFTCUTFINAL 02608 de 48

TECHNICAL MANUAL LEON CUP RACERSupensionFeaturesFront damper ZF SachsSprings Eibach front and rearFront Antiroll barRear bumper ZFRear AntirollbarDescription2 way adjustable / Aluminium body160/60/70 -80-90-100-11022x2 // 22x31 way adjustable parallel / Aluminiumbody22 x3 // 22x4BrakesBrake car featuresFront caliperFront discFront pumpFront padsRear caliperRear discRear pumpRear padsRear press reducerBrake balance1.5DescriptionAP 6P362 x 32AP 19,1 mmPagid 5F6AP 2P272x10AP 22,2 mmPagid 5F6valve 25 barMechanicalRemarksSpecial: SEAT SportSpecial: SEAT SportThick: 25 mmSolidOrange(nominal)Rim & TireTyre informationRim dimensionRim centre lockMaximum tyre dimension recommendedTyre temp difference inside / outsideMinimum cold pressure recommended1.6RemarksClick bmp10 / 20 ReboundAdjustableAdjustable in 6 positionsClick 2010”x 18” ET 365 studs x 112 mm270/660 R1820ºC1.4 barElectronic unitsElectronic MODULESECUMechatronicElectronic slip differentialLow fuel pump controlElectronic Steering rackESP unitGatewayBlack boxMXG display / loggerFuse boxSteering Driver moduleTransponderRemarksContinentalVWBorgWarnerPWM controlmoduleVWContinentalVWAudiAIMSEAT SportSEAT esPlaceEngine bayInside gear boxFDX (external)Fuel tank (external)MotorsportNo activeSeries nt Engine bay9 de 48

TECHNICAL MANUAL LEON CUP RACERModules informationMechatronicElec. Slip diff.Low fuel pumpSteering rackESPGatewaySpecific software/ mapping:Specific codifications:Interchangeable between cars:Spare part ready for plug and play:*UDS diagnosis (VW diagnosis):Modification allowed:EngineMODULES BASED IN NoYesyesYesYesYesNoNotes: Use always spare parts from SEAT Sport. Although the mentioned parts are derived from seriescars, 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 anymalfunction.Architecture Leon Cup Racer:All electronic modules are connected by CAN Bus and LIN Bus. Following the LCR CAN scheme view:10 de 48

TECHNICAL MANUAL LEON CUP RACER2DRIVERS CONTROLIn this section is explained how the driver can handle the Leon Cup Racer commands and functions.2.1Main consoleMain switch:Active the battery supply.Ignition switch: Active the power to all devices.Low beam:Active the low beam light. Highbeam and flash activation buttons are placed on thesteering wheel module.Turn light:Active the left and right turn lights.No automatic return.Brake balance: Turning the balance wheel youcan balance the brake pressure from front to back orvice 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 inpercentage.Notes: 2.2To start the engine, always proceed with this order: Main switch and later power supply. To stop theengine proceeds backwards.Steering wheel moduleThe electronic steering wheel module permits toactivate different functions without living handsfrom the steering wheel.Some buttons has double functionilySteering wheel functions:Nº1FunctionStarterConditions / RemarksActive in gear lever in “P” or “N”Active if rpm 500Speed limiterPressing the button constantly limit 60 km/h2Diff map change3 maps3Traction controlactive/deactivateSafety brakesignal buttonShort push to increase differential map numberThe diff map scrolls rotatory with 3 mapsDiff 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 rainONLY WHITH ABS UNIT ACTIVEPressing the button 3 seconds the TCS can be deactivated.“Brake signal can be activate with this button in case of brake switchfailure”11 de 48

TECHNICAL MANUAL LEON CUP RACER4Radio5Rain lightsPossible move the gear lever without push the brake pedalIMPORTANT: the use of this security button it’s under the userresponsibility.Driver voice activationMaintain pushed to talkShort push to toggle on/off6Driver fanToogle to activate7Change displayPress to change the display pages / rolling change8High beam9WiperShort push to flashLong push to toggle on/offToggle to activate.10Windscreen waterPush to activate water splash wiper activation11Drink‘ -- Tip up // TipActivates water pumpNote: Pump not supplied by SSpOrange led informs when tip up or down signal has been activateddownCAN infoUsual status: LED offLED on when there is a problem of CAN Bus communicationNotes: Although it is possible uncouple completely the steering wheel from the column with the enginerunning, 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 leveralthough the brake pedal is not pressed. Take care and advise the people around the carbecause wheels may move. 2.3Gear lever functionsThe shifting gear lever enables the different gear box modes. The features for each mode are:Gear leverModeRemarksPParking modeRReverseUse to lock the car.(Safety for team staff when car isstopped)(not allowed on the pits zone)NNeutralNo gear engaged. Traction is free.D/SAutomatic modeTip / - (TS)Manual shiftingD Automatic DriveS Automatic Sport DriveShifting through the wheel paddles12 de 48

TECHNICAL MANUAL LEON CUP RACER“P” parking mode:Use parking mode to lock the transmission trough a mechanical cable. Use only this position when youwant block the car. It’s only possible lock or unlocks the parking mode if the car is completely stopped and the brakepedal is pressed.IMPORTANT: Never try to put the gear lever in “P” if the car is not completely stopped. If thishappens 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 thebrake pedal, through the safety grey button “sign (P)” on the steering wheel module is possible tounlock 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 andbrake 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. Thegear 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 steeringpaddles.It’s possible to use “S” mode in the launching system. The gear will shift up automatically. Thedriver 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) 2.4From 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 onesecond.Car launching systemsThere 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 wheelsare absolutely stopped and brake pedal is pressed.Launching time after brake signal pedal off:13 de 48

TECHNICAL MANUAL LEON CUP RACERProcess: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, willnot 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 thegas pedal.Summarizing: Arriving from the formation lap driving in “S” or “TS stops the car on the grid linepressing the brake pedal. Push the foot throttle flat out (4200rpm) and release the brake whenyou 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 thelaunch 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 3500rpm.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 systemprocess will understand th

technical manual leon cup racer 6 de 48 1.3 body shell part number description material 01 bonnet steel 02 left / right front bonnet steel 03 left right rear bonnet steel 04 roof steel 05 luggage compartment cover steel 11 bonnet oppening carbon 12 front splitter carbon 13 fender air exit carbon 14 front bumper fiber glass 15 reat bumper

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