Seat 2015 LEON CUP RACER User manual

LEON CUP RACER
2015
TECHNICAL MANUAL

TECHNICAL MANUAL LEON CUP RACER
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TECHNICAL MANUAL LEON CUP RACER
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Table of contents
1TECHNICAL INFORMATION........................................................................................... 4
Leon Cup Racer Display............................................................................................ 41.1
Dimensions and weights............................................................................................ 51.2
Body shell .................................................................................................................... 61.3
Powertrain.................................................................................................................... 71.4
Rim & Tire.................................................................................................................... 9
1.5
Electronic units............................................................................................................ 91.6
2DRIVERS CONTROL ...................................................................................................... 11
Main console............................................................................................................. 112.1
Steering wheel module............................................................................................ 112.2
Gear lever functions................................................................................................. 122.3
Car launching systems ............................................................................................ 132.4
Speed limiter system................................................................................................ 142.5
Driver has to consider.............................................................................................. 152.6
3DISPLAY & FUSE BOX................................................................................................... 16
Display alarms and shift lights................................................................................ 163.1
Data acquisition analysis......................................................................................... 183.2
MXG channel expansion scheme.......................................................................... 193.3
Fusebox ..................................................................................................................... 213.4
Auxiliary connectors................................................................................................. 243.5
4SETTING ADJUSTMENTS............................................................................................. 27
Delivery car set-up.................................................................................................... 274.1
Steering rack centering............................................................................................ 284.2
Suspension adjustments......................................................................................... 284.3
Front Camber and Toe adjustment........................................................................ 294.4
Rear Camber and Toe adjustment ........................................................................ 294.5
Dampers ...................................................................................................................... 314.6
Antiroll bars................................................................................................................ 344.7
Kinematics................................................................................................................. 344.8
Brakes ........................................................................................................................ 364.9

TECHNICAL MANUAL LEON CUP RACER
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Aero............................................................................................................................ 374.10
5WORKSHOP MANINTENANCE.................................................................................... 38
FIRST ROLLOUT..................................................................................................... 385.1
Check list ................................................................................................................... 385.2
Vehicle & parts identification................................................................................... 395.3
Fluids information..................................................................................................... 405.3
Engine service........................................................................................................... 415.4
Air filter....................................................................................................................... 415.5
Gearbox & Slip differential service......................................................................... 435.6
FDX - Slip differential control & service................................................................. 435.7
Fuel............................................................................................................................. 445.8
Electronic modules................................................................................................... 455.9
Airjack......................................................................................................................... 465.10
6PARTS MILEAGE............................................................................................................. 47
7SAFETY............................................................................................................................. 48

TECHNICAL MANUAL LEON CUP RACER
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1 TECHNICAL INFORMATION
Leon Cup Racer Display1.1
Engine
\ Type Turbocharged; 4-cylinder in line
\ Fuel supply system Direct fuel injection
\ Displacement (cc) 1984 cc
\ Bore and stroke (mm) 82,5 x 92,8
\ Maximum power (PS/rpm) 330 PS
\ Maximum torque (Nm/ rpm) 410Nm
\ Electronic control unit Continental SIMOS
\ Exhaust / dB. Racing catalysed 104dB
\ Fuel tank capacity 55 lts Standard tank with additional
\ Speed limiter system active 60km/h
\ Launch control system active
Transmission
\ Transmission Front-wheel-drive
\ Gearbox 6 speed DSG
\ Differential VAQ ellectronically managed
\ Clutch Multi disc oil cooled
\ Shift control Electronic on steering wheel
Chassis and Suspension
\ Front suspension McPherson, adjustable in height, toe and camber
\ Anti-roll bar Front and rear adjustable
\ Rear suspension Multi-link axel, adjustable in height, toe and
camber
\ Front brakes 6-piston callipers, 362 mm steel ventilated discs
\ Rear brakes 272 mm steel discs
\ Brake pedal Unitary with brake balance regulation
\ Steering system Full Ellectrical power steering rack
\ Rims
\ ABS Removed
Body and aerodynamics
\ Roll bar Driver position FIA Homologated and Hans adapted
\ Weight 1.120 kg
\ Front Width (max) 1.950 mm
\ Rear Width (max) 1.950 mm
\ Length 4.363 mm
\ Wheel base 2.666 mm
Car check-control
\ Acquisition system AIM - MXG 28 channels + 8 analogics
\ Car check-control Auto-diagnosis OBDII / DiagRA - LE
\ Airjack Complete car kit

TECHNICAL MANUAL LEON CUP RACER
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Dimensions and weights1.2
Dimensions
Overall length
4382 mm
Overall bodywork front width
1950 mm
Measured on the mud-ward at the front axle
Overall bodywork rear width
1950 mm
Measured on the mud-ward at the rear axle
Wheel base
2665 mm
Over hang front splitter
897 mm
Over hang front bumper
868 mm
Over hang rear
820 mm
Over hang rear wing
165 mm
From the wing vertical to the bumper
Minimum ground clearance
free
70 mm is the performance recommendation
Weight:
Total weight in race conditions without fuel
1150 Kg (1)
Car balance
63,2% front <> 36,8% rear
Distribution weight/power
3,48 Kg/cv
Note:
(1) This value means the minimum weight on the “Technical Regulations” in race conditions.

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Body shell1.3
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
FIBER GLASS
16 (2014)
LEFT /RIGHT SILL TRIM PANEL
PLASTIC
16 (2015)
LEFT /RIGHT SILL TRIM PANEL
FIBER GLASS
17
LEFT / RIGHT REAR DOOR EXTENSION
CARBON (painted)
18
LEFT / RIGHT REAR FENDER
EXTENSION
CARBON (painted)
19
LEFT / RIGHT FRONT FENDER
CARBON (painted)
21
WINSCREEN
GLASS
22
LEFT / RIGHT FRONT DOOR WINDOW
GLASS
23
LEFT / RIGHT REAR DOOR WINDOW
GLASS
24
LEFT / RIGHT REAR TRIANGLE
WINDOW
PLASTIC
25
REAR WINDOW
PLASTIC

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Powertrain1.4
Engine
ENGINE FEATURES
Type
2,0 TSI / Turbocharged & direct injection
Engine identification
CJX
Cylinder capacity
1984 cc
Corrected cylinder capacity
1984 x 1,7 = 3372,8
Maximum power
242 KW (330 Hp) at 6250rpm
Maximum torque (Nm/ rpm)
410 Nm at 4600 rpm
Max rpm
6800 rpm
Specific Power
165 CV/l
Electronic control unit
CONTINENTAL SIMOS 18.1
Fuel
RON MIN 98 , RON MAX 102
Fuel Consumption
0,37 to 0,42 l/km
Exhaust / dB
Racing Catalyst FIA Homologated / 104 dB
Distribution
Chain (sealed)
Oil system
Wet sump
Water pump
One electric water pump + two auxiliary pumps
Water thermostat
Double electronic thermostat
Fan range
Operating range 92°C to 87°C
Standard Fuel tank features
Fuel tank type
Standard fuel tank from Quattro version
Capacity
55 lts Standard tank
Minimum fuel level before engine
fault
> 5 lts.
Engine power and torque curve:

TECHNICAL MANUAL LEON CUP RACER
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Gear box & Slip diff.
Gear box features
Transmission
Front wheel drive
Gear box
6 speed DSG (semi automatic gbx)
Differential
VAQ Electronic slip differential
Differential settings
3 Map available.
Map swapping through the steering wheel module green button.
MAP 1
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)
MAP 2
Like map 1, less yaw damping, 200 Nm prelock during braking
Recommended use when medium grip. (used tyres)
MAP 3
Prelock dependent from engine torque, 200 Nm prelock during
braking(releasing earlier than 2)
Recommended use when grip is low or rain
Clutch
Double multidisc clutch in oil bath
Gear box mode command
Electronic on the central gear lever
Gear shift
Paddles on the steering wheel
Gbx. Electronic Control Unit
Integrated mechatronic in oil bath
Cooling system
Exchanger oil - water
Launch control system
Activated
Down shift over rev protection
Activated / 1sec memory
Gear box Ratios
GROUP 1-2-
3-4
15
72
0,208
83
180
189
DIF
Km/h
GROUP 5-6
20
72
0,278
RPM1
GEAR
SHIFT
CUT
FINAL RATIO
1
1
1,000
GEAR
Prim
Z1
Sec
Z2
Gear
Relation
Total
Relation
3000
6500
6800
DIF
RPM
1st
13
38
0,342
0,071
26
56
58
2nd
22
45
0,489
0,102
37
80
83
1952
3rd
28
41
0,683
0,142
51
111
117
1847
4th
38
41
0,927
0,193
70
151
158
1711
5th
32
35
0,914
0,254
92
199
208
1558
6th
38
35
1,086
0,302
109
236
247
1026
3000
4000
5000
6000
7000
8000
020 40 60 80 100 120 140 160 180 200 220 240 260

TECHNICAL MANUAL LEON CUP RACER
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Supension
Features
Description
Remarks
Front damper ZF Sachs
2 way adjustable / Aluminium body
Click bmp10 / 20 Rebound
Springs Eibach front and rear
160/60/70 -80-90-100-110
Adjustable
Front Antiroll bar
22x2 // 22x3
Adjustable in 6 positions
Rear bumper ZF
1 way adjustable parallel / Aluminium
body
Click 20
Rear Antirollbar
22 x3 // 22x4
Brakes
Brake car features
Description
Remarks
Front caliper
AP 6P
Special: SEAT Sport
Front disc
362 x 32
Special: SEAT Sport
Front pump
AP 19,1 mm
Front pads
Pagid 5F6
Thick: 25 mm
Rear caliper
AP 2P
Rear disc
272x10
Solid
Rear pump
AP 22,2 mm
Rear pads
Pagid 5F6
Orange
Rear press reducer
valve 25 bar
(nominal)
Brake balance
Mechanical
Rim & Tire1.5
Tyre information
Rim dimension
10”x 18” ET 36
Rim centre lock
5 studs x 112 mm
Maximum tyre dimension recommended
270/660 R18
Tyre temp difference inside / outside
20ºC
Minimum cold pressure recommended
1.4 bar
Electronic units1.6
Electronic MODULES
Remarks
Software
Place
ECU
Continental
Motorsport
Engine bay
Mechatronic
VW
Motorsport
Inside gear box
Electronic slip differential
BorgWarner
Motorsport
FDX (external)
Low fuel pump control
PWM control
module
Series
Fuel tank (external)
Electronic Steering rack
VW
Motorsport
Front subframe
ESP unit
Continental
No active
Cockpit
Gateway
VW
Series adapted
Cockpit
Black box
Audi
Motorsport
Cockpit
MXG display / logger
AIM
Motorsport
Cockpit
Fuse box
SEAT Sport
Motorsport
Cockpit
Steering Driver module
SEAT Sport
Motorsport
Cockpit
Transponder
XXX
Engine bay