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

WORKSHOP MANUAL LEON CUP RACER
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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.

WORKSHOP MANUAL LEON CUP RACER
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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

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
Engine bung set -VAS 6122-

Hose clip pliers -VAS 6362-

Support tool -T10038-
Removing
Caution
Risk of malfunctions caused
by dirt.
Observe →Chapter „Cleaning
rules“.
–
Drain coolant →Chapter.
–
Removing front exhaust pipe
with catalytic converter
→Chapter
–
Remove the air filter housing
→Chapter.
–
Remove Lambda probe -
G39- →Chapter „Lambda
probe - overview“.

WORKSHOP MANUAL LEON CUP RACER
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–
Release the hose clamp -
2-.
–
Remove bolt -1- and press
air pipe (left-side) towards
left slightly.
–
Remove coolant hose -
arrow-.
–
Separate connectors -1- and
-2-. Open retainer -3-.

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–
Remove bolt -1- for earth
cable and remove coolant
hose -2-.
–
Pull off connector -arrows-.
–
Release fastener -arrow-
and remove wiring duct -4-
upwards from bracket.
–
Unscrew the bolts -1, 2
and 3-. Swivel coolant
pipe to the side.
–
Remove Lambda probe 1
before catalytic converter -
GX10- →Chapter.

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–
Remove actuators for
camshaft adjustment -
arrows-.
–
Removing ignition coils
with output stages
→Chapter
–
Remove bolts -arrows-
and nut -1-.
–
Detach heat shield -2-.

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–
Remove bolt -1- and
loosen bolt -3-.
–
Remove bracket -2- for
turbocharger.
–
Detach electrical
connectors -1, 3-.
–
Press release tabs on
crankcase breather hose -
2- and detach hose.

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–
Remove bolts -1- and
detach connection.
–
Unscrew bolts -2, 3- and
detach oil supply line and
oil return line.
–
Release hose clip -arrow-.
Note
The following procedure is
necessary to provide more
space between the cylinder
head and bulkhead.
–
Unscrew bolts -1, 2, 3-
and remove pendulum
support.

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–
Pull engine back approx. 20
mm with tensioning strap -
T10038-.
–
Remove nuts -arrows-.
–
Detach turbocharger from
cylinder head.
Installation
Installation is carried out in
the reverse order; note the
following:
Note

Replace the seals, the
gaskets, O-rings and the
self-locking nuts.

Lubricate studs for
turbocharger with high-
temperature paste. For
high-temperature paste
refer to →Electronic parts
catalogue.

Fill turbocharger with
engine oil at connection
for oil supply line.

The brackets for the hoses
and the supercharger air
system tubes must be free
from oil and grease for
fitting.

Secure all hose
connections with the
correct type of hose clips
(same as original
equipment) →Electronic
parts catalogue.
–
Install front exhaust pipe
with catalytic converter
→Chapter.
–
Align the exhaust system
so it is free of stress

WORKSHOP MANUAL LEON CUP RACER
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→Chapter.
–
Fill up with coolant
→Anchor.
–
Check oil level
→Booklet501.
Note
After installing turbocharger,
allow engine to idle for
approx. 1 minute and do not
rev up immediately to ensure
turbocharger is supplied with
oil.
Tightening torques

→Chapter „Turbocharger,
exploded view“

→Chapter „Air filter
cartridge: Assembly
overview“

→Chapter „Lambda probe
- overview“

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2IGNITION SYSTEM
Ignition system: Assembly overview
2.1
1 -
Bolt

replace

20 Nm.

Tightening torque influences functions of knock sensor
2 -
Knock sensor I -G61-

remove and install →Chapter „Knock sensor 1 -G61-: Removing and installing“
3 -
Spark plug

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
30 Nm.

Remove and install with key -3122 B-
Intervals for changing filter
→Booklet 501
4 -
Ignition coil with output stage

Ignition coil 1 with output stage -N70-

Ignition coil 2 with output stage -N127-

Ignition coil 3 with output stage -N291-

Ignition coil 4 with output stage -N292-

Tightening torque: 10 Nm

remove and install →Chapter „Ignition coils with output stage: removing and fitting“
5 -
Bolt.

9 Nm
6 -
Hall sender 3 -G300-

Removing and installing Hall sender 3 -G300- →Chapter „Removing and installing
Hall sender 3 -G300-“

Renew O-ring.
7 -
O-ring

Renew if damaged
8 -
O-ring

Renew if damaged
9 -
Hall sender -G40-

Removing and installing Hall sender -G40- →Chapter „Removing and installing Hall
sender“.
10 -
Bolt

9 Nm
11 -
O-ring

Renew if damaged
12 -
Engine speed sender -G28-

Check O-ring for damage

remove and install →Chapter „Removing and installing engine speed sender -G28-“
13 -
Bolt