Seat LEON CUP RACER 2011 User manual

LEON CUP RACER
2014
TECHNICAL MANUAL

TECHNICAL MANUAL LEON CUP RACER
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INDEX
1 GENERAL INFORMANTION .................................................................................................... 4
Vehicle & parts identification........................................................................................ 41.1
Dimensions and weights ............................................................................................... 51.2
Fluids and tires information .......................................................................................... 61.3
2 TECHNICAL SPECIFICATIONS ................................................................................................. 7
Engine............................................................................................................................ 72.1
Engine control & service ............................................................................................... 82.2
Fuel................................................................................................................................ 92.3
2.3.1 Air filter................................................................................................................ 10
Gear box ...................................................................................................................... 112.4
Gearbox control & service........................................................................................... 122.5
FDX - Slip differential control & service ...................................................................... 122.6
Gear lever functions.................................................................................................... 132.7
2.7.1 Launch control porcess ....................................................................................... 14
2.7.2 Central console command................................................................................... 15
2.7.3 Steering wheel functions..................................................................................... 15
Brakes.......................................................................................................................... 172.8
Dampers and Springs.................................................................................................. 182.9
3 SETTING ADJUSTMENTS ...................................................................................................... 22
Tire............................................................................................................................... 223.1
4 Front suspension ................................................................................................................. 24
Anti roll bars ................................................................................................................ 244.1
Kinematics ................................................................................................................... 244.2
4.2.1 Front Camber and Toe adjustment.................................................................... 26
Rear suspension......................................................................................................... 284.3
4.3.1 Rear Caber regulation........................................................................................ 28
Car set up table ........................................................................................................... 294.4
Alignment .................................................................................................................... 304.5
5 ELECTRIC.............................................................................................................................. 31
General information................................................................................................... 315.1

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Modules...................................................................................................................... 315.2
Data Logger ................................................................................................................ 325.3
5.3.1 MXG channel expansion scheme...................................................................... 34
Display........................................................................................................................ 365.4
5.4.1 Driver pages:...................................................................................................... 36
5.4.2 Display alarms and shift lights ......................................................................... 37
Transponder:.............................................................................................................. 385.5
Extra connectors:........................................................................................................ 385.6
6 Bodywork & aero................................................................................................................. 39
Material of bodywork panel........................................................................................ 396.1
Rear wing..................................................................................................................... 406.2
7 SAFETY................................................................................................................................. 41
8 Parts mileage....................................................................................................................... 42
ANNEXE (Torques)

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1GENERAL INFORMANTION
Vehicle & parts identification1.1
V.I.N. (Vehicle Identification Number) is welded on the roll cage
Nº: VSSMK35F4ESSPxxxx
Engine identification number
Nº: CJX xxxxxxx
Gear box identification number engraved on the aluminum carcass.
Nº: C0xx
aluminum carcass.

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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
2660 mm
Over hang front
897 mm
Over hang rear
825 mm
Over hang rear wing
168 mm
From the wing verticalto the bumper
Minimum body work height
1360 mm
At ride height 60mm to the ground
Minimum ground clearance
free
60 mm is the performance recommendation
Weight:
Total weight in race conditions without fuel
1150 Kg (1)
Car balance
63,2% front <> 56,8% rear
Distribution weight/power
1,48 g/cv
Note:
(1) This value

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Fluids and tires information1.3
Fluids
From
Remarks
Quantity
Engine
CASTROL EDGE w10-60
VN0000052500
5. lts (filter)
0.5 lts
Gear box
VW-Audi
_G052182A2
Substitution 5.2 lts
Mechatronica 3 4 lts
Electronic Slip
Differential
VW
G 060 175 A2
Unit 0.7 lts
Substitution 0.5 lts
Drive shaft
VW-Audi
VN0000040401
100gr
Coolant
VN0000060400
5 lts
Brake fluid
CASTROL SRF
VN0000062400
Fuel
PANTA
NS 102 Ron
Windscreen cleaner
Free
Notes:
SEAT Leon Eurocup: Use only the fuel distributed on the race track. (technical & sportive regulations).

The fuel allowed on the SEAT Eurocup championship is marked with an identifier to permit the
marshals control. If for any reason (in a previous test,,, etc) you were using other fuel you must
replace all fuel in the fuel tank for the Eurocup one.

level control if there

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2TECHNICAL SPECIFICATIONS
Engine2.1
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 / 100 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
Engine power and torque curves:

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Engine control & service2.2
Following the more frequent maintenance issues. For more detailed maintenance or parts substitution
information download yourself www.seat-sport.com .
Control routine before start to run:
Check the oil level: It has to be at top of the level dipstick indication in cold conditions. It is possible
to fit up to 1mm over the max level.
Check the water level before start.
With the engine running, check there is any oil or water or fuel leakage.
Check the fan functionality. Operating range 92°C to 87°C.
Don not push the engine until the water temperature its upper to 80°C.
Maintenance routine:
Change the engine oil and oil filter in the indicated mileage.
Use always the fluids and spare parts from VW group original parts , detailed on the Leon Cup Racer
parts catalogue
Clean and service the air filter each event. In urban circuits is recommended clean or replace more
frequently.
Check that the alternator belt is clean and there inside the PoliV.
Often clean the radiator and intercooler panel.
If any doubt, contact to the SEAT Sport service.
Distributial seal view Turbo charger seal view
Parts subject to frequent service:
Engine
Torque
Remarks
Oil drain plug
By hand
Change the plastic cap (provided with the oil
filter)
Oil filter plastic cover
50 Nm
Oil filter
<<
O
Oil dipstick view.

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Fuel2.3
The fuel tank is coming from series using the standard flow fuel pump and in additional a second flow pump on
the opposite side.
The Leon Cup Racer body shell is ready to add an additional fuel tank. This tank is additional, connected in line
and supplying the fuel to the first one.
Standard Fuel tank features
Fuel tank type
Standard fuel tank from Quattro version
Capacity
55 lts Standard tank / *option 60 lt additional fuel tank (LR
version)
Minimum fuel level before engine fault
> 5 lts.
Additional fuel tank features
Features
FT3 FIA Homoogated
Capacity
60 lt additional fuel tank // possible to reduce the capacity
by adding balls.
main tank by gravity.
Notes:
The Quattro version fuel tank permits use a straight exhaust decreasing the fuel temperature for
the exhaust irradiation. Check all tack protections are in good conditions.
After a crash or out track driving check the inner flow fuel pumps fixations.
Fuel tank drain:
Hydraulic: There is a FIA fuel
The pump activation system is connected to the battery directly. For safety, is strongly recommended to
carry out the process with the main switch off.
- View (a) - - View (b) -
Note:
During the drain process is strongly recommended to stop the process at the end. This is for no
damaged fuel pump running without fuel.
On the Leon Cup Racer parts catalogue it is available the extraction kit.
To carry out this procedure is recommended to connect the extraction tool to the battery help
connector on the car.

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2.3.1 Air filter
Air filter
Torque
Remarks
Air filter substitution
By hand
4 small bolts over plastic. Becareful.
Air filter clean
1) Clean the cotton air filer following the procedure
showed.
2) DO NOT use compressed air or high-pressure air to
clean.
Use only the recommended oil for cotton filters.
Notes:
The air
The air filter clean and right oiled is mainly for the turbo charger
live. Is strongly recommended follow the clean procedure as well
as the timing.
After a use in rain conditions is recommended the cleaning or
change.
Air filter std. clean procedure

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Gear box2.4
Gear box features
Transmision
Front wheel drive
Gear box
6 speed DSG
Differential
Electronic slip differential FDX
Differential settings
3 maps / driver selection active (steering wheel module)
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
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
Rel
canvi
Rel
total
3000
6500
6800
DIF
RPM
1ª
13
38
0,342
0,071
26
56
58
2ª
22
45
0,489
0,102
37
80
83
1952
3ª
28
41
0,683
0,142
51
111
117
1847
4ª
38
41
0,927
0,193
70
151
158
1711
5ª
32
35
0,914
0,254
92
199
208
1558
6ª
38
35
1,086
0,302
109
236
247
1026
4500
5500
6500
7500
020 40 60 80 100 120 140 160 180 200 220 240 260
3000
4000
5000
6000
7000
8000
020 40 60 80 100 120 140 160 180 200 220 240 260

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Gearbox control & service2.5
Following the more frequent maintenance issues. For more detailed maintenance or parts substitution
www.seat-sport.com .
Control routine before start:
Check that there is any oil leakage
Operating range 70°C to 135°C.
Do not load the engine until the gear box temperature its upper to 70°C. (control on the display
screen).
Check the SEAT Sport seal is in good condition.
Note:
Routine maintenance:
Change the gear box oil and filter in the indicated mileage. (see mileage table)
Oil filter, as well as the rest of the engine spare parts must be VW group original parts, detailed on the
Leon Cup Racer parts catalogue.
any oil leakage there is not necessary any level control.
www.seat-sport.com .
Mechatronica (green narrow)

FDX - Slip differential control & service2.6
Routine maintenance:
Change the FDX oil in the indicated mileage. (See mileage table). Use only the recommended oil.

Send to SEAT Sport for revision when recommended mileage is reached.
Slip differential jobs
Torque
Remarks
FDX oil level check cap
15 Nm
Change every time
a) Gear box –mechatronica view-
b) Gear box –gear box seal view-

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Note:
In case of disassemble the unit from the car, the unit must be positioned in vertical position, as is
shown in the picture, to avoid any oil leakage.
Gear lever functions2.7
The gear lever, placed on the center tunnel, enables to activate different command modes. The features for
each command mode are:
Gear lever position
Mode
Remarks
P
Parking mode
Use to block the car
Safety for team staff when car is stopped
R
Reverse
(not allowed on the pits zone)
N
Neutral
No gear engaged
D/S
Automatic mode
D= no racing mode
S= Racing mode / high engine speed shifting / racing
down shift.
Tip + / -
Manual shifting
Shifting through the gear lever +/- mode or using
steering wheel paddles
Parking mode is a lever position that fixes the transmission trough a mechanical cable. Use only this position
when you want block the car.
or removes the parking mode if the car is completely stopped and the brake
pedal is pressed.
might be seriously damaged.
If for any reason the brake signal is not available and , the grey
button, sign (P) , on the steering wheel module permit to unlock the gear lever command.
to put on and take out the mode if the car is complete stopped and
brake pedal is pressed.
ible move the car to park, etc, pushing externally. (pit lane use)
a) FDX view –level cap and seal)
c) FDX level cap –bottom view-

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automatic mode:
Not advisable for race. ock zone. The gear
shifting in a low range.
S automatic mode:
From on the gear lever
gear mode symbol is showed on the display screen.
Not recommended for race.
Aggressive in upshifting and down shifting.

driver can pass to Tip mode in any moment.

to pass and in any moment.
2.7.1 Launch control porcess
Launch control system permit reach a given level of engine speed with the clutch activate and gear inserted.
This system when wheels are absolutely stopped and brake pedal is pressed.
Process:
1. Car have to be stopped
2. Brake pedal pushed. (Brake press >10 bar)
3. Gear lever in or pmode (gear lever on the right side)
Accelerate the engine at the choice level. It is advisable between 3600 to 4500 rpm. Engine
speed limit is at 4500 rpm.
4. Release the brake pedal and car will go ahead.
Notes:
Using the mode, up shift is automatic.
U to pay attention because engine speed limit arrives earlier and
gear will not shift up automatically. (engine limiter active)
There is a delay between the brake pedal off and car launch. Driver has to be in account.

Gear lever command
Shift padle view

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2.7.2 Central console command
There are four commands on the center console:
Main switch (+30) (red protection)
Contact switch. (+15) (yellow protection
Low beam
Turn light
2.7.3 Steering wheel functions
The steering wheel electronic give the most driver location in a very ergonomic use.
Steering wheel functions:
Nº
Function
Conditions / Remarks
1
Starter
Active if < 500 rpm
2
Diff map change
3 maps
Short push to increase differential map number
The diff map scrolls rotatory with 3 maps
Diff map number is
Map 1: High locking torque
Map 2: Medium locking torque
Map 3: Medium locking in and high locking out of the corners
3
Safety brake
signal
Brake signal activation directly.
Possible move the gear lever without push the brake pedal.
IMPORTANT: the use of this
4
Radio
Driver voice activation
Maintain pushed to talk
5
Rain lights
Short push to toggle on/off
6
Driver fan
Toggle to activate
7
No active
8
Lights
Short push to flash
Long push to toggle on/off
9
Wiper
10
Windscreen water
Push to water splash + wiper scanning
11
Drink
Activates a water pump.
Note: Pump not supplied by SSp.

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Brakes2.8
The following table shows the parts features mounted on the LCR.
Brake car features
Description
Remarks
Front caliper
AP 6P
Special: SEAT Sport
Front disc
362 x 32
Special: SEAT Sport
Front pump
AP 17,3 mm
Front pads
Galfer RX
25 mm
Rear caliper
AP 2P
Rear disc
272x10
Solid
Rear pump
AP 22.2 mm
Rear pads
Galfer RW
Rear press reducer
Single valve 25 bar
(nominal)
Brake balance
Mechanical
Notes:
The front calipers are internally different from the AP std parts. Use always spare parts from the SEAT
Leon Cup Racer Parts Catalogue.
The front discs for the SEAT Cup Racer have 11 bracket lengths. Use always spare parts from the SEAT
Leon Cup Racer Parts Catalogue.
The rear caliper pressure is limited. The brake pressure value showed on the dashboard is previous to
the reduction press valve.
Following the brake pump range available.
MASTER CILINDER
Push Rod
Remarks
AP 15 MM
PRT 110
AP 15.9 MM
PRT 110
AP 16.8 MM
PRT 110
AP 17.8 MM
PRT 110
SEA Sport car delivery
AP 19,1 MM
PRT 110
AP 20,6 MM
PRT 110
AP 22,2 MM
PRT 110
SEAT Sport car delivery
AP23,8 MM
PRT 110
Brake balance.
It is recommended keep the same pump diameter balance.
The brake balance is mechanic through the remote brake bias adjuster.
Do not press the brake pedal when you are adjusting the brake balance.
the front / rear pressure and the balance
percentage. The recommended percentageis 60% front. (car delivery)
Balance value: FRONT X 100
FRONT + REAR

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Dampers and Springs
2.9
Front Damper information
STTV technology (Single Tube Twin Valve)
2 way adjustable
Aluminium outer housing
Upside down cartridge
Friction optimized guide bushings and seals

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Notes:
Start to count the clicks from close (+) to open.
Be careful, do not squeeze to close strong the last click.
Rear Damper information
The rear damper is equipped with a 1-Way parallel adjuster.
Each click adjusts the bump and rebound characteristics parallel.