Seat 2015 LEON CUP RACER Instruction manual

LEON CUP RACER
2015
WORKSHOP MANUAL

WORKSHOP MANUAL LEON CUP RACER
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WORKSHOP MANUAL LEON CUP RACER
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INDEX
1 TURBOCHARGER.................................................................................................................... 3
Turbocharger, exploded view ....................................................................................... 31.1
Turbo compressor: removing and fitting ...................................................................... 91.2
2 IGNITION SYSTEM................................................................................................................ 18
Ignition system: Assembly overview ........................................................................... 182.1
Ignition coils with output stage: removing and fitting................................................ 202.2
3 OIL SUMP............................................................................................................................. 22
Assembly overview - sump, oil pump ......................................................................... 223.1
Removing and installing oil level/oil temperature sender -G266-.............................. 283.2
Remove and install the lower element of the oil tray ................................................ 293.3
Remove and install the upper element of the oil tray ................................................ 333.4
4 INTAKE MANIFOLD WITH THROTTLE................................................................................... 39
Intake manifold: Assembly overview .......................................................................... 394.1
Exploded view - fuel rail, direct injection.................................................................... 41
4.2
Exploded view - fuel rail, intake manifold injection.................................................... 444.3
Intake manifold: Removing and installing................................................................... 464.4
Removing and installing throttle valve module -GX3- ................................................ 534.5
5 ALTERNATOR ....................................................................................................................... 56
Alternator without sliding bushes -exploded view-.................................................... 565.1
Removing and installing the alternator, vehicles with 1.8 litre TSI engine................. 575.2
Tightening torques: Alternator: .................................................................................. 615.3
6 DIFFERENTIAL ...................................................................................................................... 62
Assembly overview –Front differential lock............................................................... 626.1
Removing front differential lock ................................................................................. 636.2
Installing front differential lock................................................................................... 676.3

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1TURBOCHARGER
Turbocharger, exploded view
1.1
Part I
Part II →Anchor
1 -
O-ring

Renew

Lubricate lightly with engine oil

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2 -
Bolt

9 Nm.
3 -
Coolant supply line
4 -
O-ring

Renew

Lubricate with coolant
5 -
Seal

Renew
6 -
Nut

Renew

25 Nm.
7 -
Turbocharger

remove and install →Chapter
8 -
Oil supply line
9 -
Heat shield
10 -
Bolt

9 Nm.
11 -
Nut

9 Nm.
12 -
Bolt

9 Nm.
13 -
O-ring

Renew

Lubricate lightly with engine oil
14 -
Bolt

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
9 Nm.
15 -
Bolt

9 Nm.
16 -
Coupling
17 -
O-ring

replace
18 -
Bolt

9 Nm.

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Part II
Part I →Anchor
1 -
Bolt

9 Nm.
2 -
Oil return line
3 -
O-ring

Renew

WORKSHOP MANUAL LEON CUP RACER
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
Lubricate lightly with engine oil
4 -
Bolt

9 Nm.
5 -
Charge pressure positioner -V465-
6 -
Nut

If nut has been loosened, charge pressure positioner -V465- must be renewed

10 Nm.
7 -
Bolt

10 Nm.
8 -
Coupling
9 -
O-ring

replace
10 -
Bolt

7 Nm.
11 -
Turbocharger air recirculation valve -N249-

Note installation position →Fig.
12 -
O-ring

Renew
13 -
Turbocharger

remove and install →Chapter
14 -
O-ring

Renew

Lubricate with coolant
15 -
Bolt

9 Nm.

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16 -
Bolt

9 Nm.
17 -
Bolt

9 Nm.
18 -
Coolant return line
19 -
O-ring

Renew

Lubricate with coolant
20 -
O-ring

Renew

Lubricate lightly with engine oil
21 -
Bolt

Coat thread with high-temperature paste; for high-temperature paste refer to
→Electronic parts catalogue

30 Nm.
22 -
Support

For turbocharger
23 -
Bolt

30 Nm.
24 -
Bolt

9 Nm.

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Fitting location of turbocharger
air recirculation valve -N249-
–
Note installation position -
arrows-.
Turbo compressor: removing and
1.2
fitting
Caution
If a mechanical fault is discovered on the turbocharger
(e.g. a destroyed compressor impeller), it is not
sufficient to just renew the turbocharger. To avoid any
subsequent damage, the following work must be
carried out:

Check air cleaner housing, air filter element and air
hoses for dirt and foreign particles.

Check the whole charge air path and charge air
cooler for foreign objects.

If foreign matter is found in the charge air system,
clean all relevant ducts and hoses and renew
charge air cooler if necessary.
Special tools and workshop equipment required