LEON CUP RACER - LMS Engineering
LEON CUP RACER2015TECHNICAL MANUAL
TECHNICAL MANUAL LEON CUP RACER1 de 44
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 . 142.4Standing start procedures . 152.5Speed limiter system . 152.6Driver has to consider . 162.7Display alarms and shift lights . 12DISPLAY & FUSE BOX . 173.1Display alarms and shift lights . 183.2Data acquisition analysis . 193.3MXG channel expansion scheme . 203.4Fusebox . 223.5Auxiliary connectors . 24SETTING ADJUSTMENTS . 264.1Car delivery set-up . 264.2Steering rack centring . 274.3Suspension adjustments . 274.4Front Camber and Toe adjustment . 274.5Rear Camber and Toe adjustment . 284.6Dampers. 294.7Antiroll bars . 314.8Kinematics . 324.9Brakes . 344.10Aero . 342 de 44
TECHNICAL MANUAL LEON CUP RACER5WORKSHOP MAINTENANCE . 355.1First rollout . 355.2Check list . 355.3Vehicle & parts identification . 365.3Fluids information . 375.4Engine service. 375.5Air filter . 385.6Gearbox control & service . 395.7FDX - Slip differential control & service. 395.8Fuel . 405.9Electronic modules . 415.10Airjack . 426PARTS MILEAGE. 437SAFETY . 443 de 44
TECHNICAL MANUAL LEON CUP RACER1TECHNICAL INFORMATION1.1Leon Cup Racer DisplayEngine\ Type\ Fuel supply system\ Displacement (cc)\ Bore and stroke (mm)\ Maximum power (hp/rpm)\ Maximum torque (Nm/ rpm)\ Electronic control unit\ Exhaust/dB.\ Fuel tank capacity\ Speed limiter system\ Launch control systemTransmission\ Transmission\ Gearbox\ Differential\ Clutch\ Shift controlChassis and Suspension\ Front suspension\ Anti-roll bar\ Rear suspension\ Front brakes\ Rear brakes\ Brake pedal\ Steering system\ Rims\ ABSTurbocharged; 4-cylinder in lineDirect fuel injection1984 cc82,5 x 92,8330 hp / 6200 rpm410Nm / 2000 to 5000 rpmContinental SIMOSRacing catalysed 104dB55 l standard quattro version tankActive 60km/hAvailableFront-wheel-drive6 speed DSG dual clutch S-tronicVAQ electro-hydraulic in front axleTwo electro-hydraulically operated oil-immersedmulti-plate clutchesElectronic on steering wheelMcPherson, adjustable in height, toe and camberFront and rear adjustableMulti-link axle, adjustable in height, toe andcamber6-piston callipers, 362 mm steel ventilated discs272 mm steel discsUnitary with brake balance regulationFull electrical power steering rackSeat Sport 10”x18”RemovedBody and aerodynamics\ Roll bar driver position\ Weight\ Front width (max)\ Rear width (max)\ Length\ Wheel baseFIA homologated and Hans adapted1.120 kg1.950 mm1.950 mm4.363 mm2.666 mmCar check-control\ Acquisition system\ Car check-control\ Airjack\ Fire extinguishing systemAIM - MXG 28 channels 8 analogicsAuto-diagnosis OBDII / DiagRA - LEComplete car kitOMP CESAL 24 de 44
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 clearanceMeasurements4382 mm1950 mm1950 mm2665 mm897 mm868 mm820 mm165 mmfreeWeightTotal weight in race conditions without fuelCar balanceDistribution weight/powerRemarksMeasured on the mud-ward at the front axleMeasured on the mud-ward at the rear axleFrom the wing to the bumper70 mm is the performance recommendationMeasurements1150 kg (1)63,2% front 36,8% rear3,48 kg/hpNote:(1) This value means the minimum weight on the “Technical Regulations” in race conditions.5 de 44
TECHNICAL MANUAL LEON CUP RACER1.3Body shellPart number0102030405111213141516 (2014)16 (2015)1718192122232425DescriptionBonnetLeft / right front bonnetLeft / right rear bonnetRoofLuggage compartment coverBonnet openingFront splitterFender air exitFront bumperRear bumperLeft / right sill trim panelLeft / right sill trim panelLeft / right rear door extensionLeft / right rear fender extensionLeft / right front fenderWindscreenLeft / right front door windowLeft / right rear door windowLeft / right rear triangle windowRear nCarbonFiberglassFiberglassPlasticFiberglassCarbon (painted)Carbon (painted)Carbon (painted)GlassGlassGlassPlasticPlastic6 de 44
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 rangeFuel tankFuel tank featuresFuel tank typeCapacityMinimum fuel level before enginefaultDescription2,0 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 CDescriptionStandard fuel tank from Quattro version55 l Standard tank 5 lEngine power and torque curve:7 de 44
TECHNICAL MANUAL LEON CUP RACERGear box & Slip diff.Gear box l settingsMAP 1MAP 2MAP 3ClutchGear box mode commandGear shiftGearbox Electronic Control UnitCooling systemLaunch control systemDown shift over rev protectionDescriptionFront wheel drive6 speed DSG (semi-automatic gearbox)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 preload during braking.Recommended use when grip is high (new tyres).Like map 1, less yaw damping, 200 Nm preload during braking.Recommended use when medium grip (used tyres).Preload dependent from engine torque, 200 Nm preload 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 1-2-3-415720,20883180189GROUP 117158208247120160FINAL 802002202402608 de 44
TECHNICAL MANUAL LEON CUP RACERSuspensionFeaturesFront damper ZF SachsEibach springs front and rearFront antiroll-barRear bumper ZF SachsRear antiroll-barDescription2 way adjustable / Aluminium body160/60/70-80-90-100-11022x2 // 22x31 way adjustable / Aluminium body22x3 // 22x4BrakesBrake car featuresFront calliperFront discFront pumpFront padsRear calliperRear discRear pumpRear padsRear press reducerBrake balanceDescriptionAP 6P362 x 32AP 19,1 mmPagid 5F6AP 2P272x10AP 22,2 mmPagid 5F6Pressure limiting valve 25 barMechanical1.5RemarksSpecial: SEAT SportSpecial: SEAT SportThick: 25 mmSolidOrangeNominalRim & TireTyre informationRim dimensionRim centre lockMaximum tyre dimension recommendedTyre temp difference inside/outsideMinimum cold pressure recommended1.6RemarksClicks: bump 10 / rebound 20AdjustableAdjustable in 6 positionsClicks: 20 bump/reboundDescription10”x18” 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 control moduleVWContinentalVWAudiAIMSEAT SportSEAT otorsportNot activeSeries ceEngine bayInside gear boxFDX (external)Fuel tank (external)Front Engine bayMechatronicElec. 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 informationModules based in NoYesYesYesYesYesNo9 de 44
TECHNICAL MANUAL LEON CUP RACERNotes: 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 RacerAll electronic modules are connected by CAN Bus and LIN Bus. Following the LCR CAN scheme view:10 de 44
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: Activates the battery supply.Power switch: Activates the power to all devices.Low beam: Activates low beam light. High beamand flash activation buttons are placed on thesteering wheel module.Blinker: Activates the left and right turn lights. Noautomatic return.Brake balance: Turning the balance wheel you canbalance the brake pressure from front to back or viceversa.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.Note: 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 removing handsfrom the steering wheel.Some buttons have double functionality.Steering wheel functions:NºFunctionStarter1Conditions / RemarksActive in gear lever in “P” or “N”Active if rpm 500Speed limiterPressing the button constant limit 60 km/h2Diff map change3 maps3Safety brakesignal button4Radio5Rain lightsShort 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: Use 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 rainBrake signal can be activated with this button in case of brake switchfailureMakes possible to move the gear lever without pushing the brake pedalIMPORTANT: the use of this security button is under user’sresponsibilityDriver voice activationMaintain pushed to talkShort push to toggle on/off6Driver fanToggle to activate7Change displayPress to change the display pages / rolling change11 de 44
TECHNICAL MANUAL LEON CUP RACER8High beam9WiperShort push to flashLong push to toggle on/offToggle to activate10Windscreen waterPush to activate water splash wiper activation11Drink-- Tip up // Tip downCAN infoActivates water pumpNote: Pump not supplied by SSpOrange led informs when tip up or down signal has been activatedUsual status: LED offLED on when there is a problem of CAN Bus communicationNotes: 2.3Although it is possible to uncouple completely the steering wheel from the column with the enginerunning, is not advisable (causes fault messages on the OBD).Be careful with the “Safety brake signal button”. This button permits putting in Neutral the gearlever although the brake pedal is not pressed. Take care and advise the people around the carbecause wheels may move.Display alarms and shift lightsCar delivery alarm configurationNotes: LED 1 yellow alarm light: Low oil pressure. If no red alarm follows you can continue. If alarmdisappears you can continue pushing. Check the oil level when back into the pit.LED 2 red alarm light POP UP: Very low oil pressure. Big risk to break the turbo or to damagethe engine. Seat Sport recommends slowing down and entering to the pit-lane or stopping in asafe place.LED 3 purple alarm light: Battery voltage low warning. You can continue, check the alternatorand the alternator poly-V belt.LED 4 yellow alarm light: Fuel pressure low warning. You can continue, check the fuel level.LED 5 yellow alarm light: water temperature high. Pay attention, drive out of slipstream andkeep an eye on the values. If no red alarm follows you can continue. If alarm disappears you cancontinue pushing.LED 6 red alarm light: water temperature too high. Drive out of slipstream and keep an eye onthe values. Some torque reductions will appear but you can continue.LED 6 red alarm POP-UP message: Critical water temperature. Seat Sport recommendsslowing down and entering to the pit-lane or stopping in a safe place, to avoid damaging theengine.LED 7 white alarm light: Gearbox oil temperature high. Drive out of slipstream and keep an eyeon the values if not some torque reductions will appear. You can continue.LED 8 blue alarm light: Intake air temperature high. Drive out of slipstream and keep an eye onthe values if not some torque reductions will appear. You can continue.12 de 44
TECHNICAL MANUAL LEON CUP RACER LED 8 red alarm light: Steering initialization needed (it will appear each time the car is switchedon). Turning the steering wheel left and right should disappear. If not, there is a problem in theelectrical steering rack.13 de 44
TECHNICAL MANUAL LEON CUP RACER2.4Gear 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 zoneNNeutralNo gear engaged. Traction is free.D/SAutomatic modeTip / - (TS)Manual shiftingD: Automatic DriveS: Automatic Sport DriveShifting through the wheel paddles“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 to lock or unlock the parking mode if the car is completely stopped and thebrake pedal 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 show 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 Ti
TECHNICAL MANUAL LEON CUP RACER 10 de 44 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
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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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