Seat Leon Cup Racer TCR 2016 User manual

2
INDEX
1TECHNICAL INFORMATION........................................................................................... 4
SEAT Leon Cup Racer TCR display ....................................................................... 41.1
Dimensions and weight.............................................................................................. 51.2
Body-shell.................................................................................................................... 61.3
Powertrain.................................................................................................................... 71.4
Wheels ......................................................................................................................... 91.5
Electronic units............................................................................................................ 91.6
2DRIVER CONTROL......................................................................................................... 10
Main panel................................................................................................................. 102.1
Steering wheel module............................................................................................ 102.2
Display alarms and shift lights................................................................................ 112.3
Gearbox functioning................................................................................................. 132.4
Standing start procedure......................................................................................... 132.5
Speed limiter (Virtual Safety Car) .......................................................................... 142.6
Driver has to consider.............................................................................................. 142.7
3ELECTRONICS................................................................................................................ 15
AIM MXG ................................................................................................................... 153.1
MXG connection schemes...................................................................................... 163.2
Data acquisition........................................................................................................ 173.3
Fusebox ..................................................................................................................... 193.4
Fuel level display...................................................................................................... 213.5
Auxiliary connectors................................................................................................. 223.6
4SETTING ADJUSTMENTS............................................................................................. 25
Standard set-up ........................................................................................................ 254.1
Steering rack centering............................................................................................ 264.2
Suspension................................................................................................................ 264.3
Front camber and toe adjustments........................................................................ 264.4
Rear camber and toe adjustments......................................................................... 274.5
Dampers..................................................................................................................... 284.6
Anti-roll bars.............................................................................................................. 304.7
Kinematics................................................................................................................. 314.8

3
Brakes ........................................................................................................................ 334.9
Aero............................................................................................................................ 334.10
5WORKSHOP MAINTENANCE....................................................................................... 34
First roll-out................................................................................................................ 345.1
Check-list................................................................................................................... 345.2
Body-shell and engine identification...................................................................... 355.3
Fluids.......................................................................................................................... 365.4
Engine........................................................................................................................ 365.5
Air filter....................................................................................................................... 375.6
SADEV ST82-17 gearbox....................................................................................... 385.7
LSD –Limited Slip Differential................................................................................ 385.8
Fuel tank .................................................................................................................... 395.9
Airjacks....................................................................................................................... 425.10
6PARTS MILEAGE............................................................................................................. 44
7SAFETY............................................................................................................................. 45

4
1 TECHNICAL INFORMATION
SEAT Leon Cup Racer TCR display1.1
Engine
\ Type Turbocharged; 4-cylinder in line
\ Fuel supply system Direct fuel injection
\ Cylinder capacity 1984 cm3
\ Bore and stroke 82,5 mm x 92,8 mm
\ Maximum power 330 HP / 6250 rpm
\ Maximum torque 410 Nm / 2000 to 5000 rpm
\ Electronic control unit Continental SIMOS
\ Exhaust Twin-end racing catalysed 114 dB
\ Fuel tank 100 l FIA FT3 Fuel Tank
\ Speed limiter (Virtual Safety Car) 5 variable speeds
\ Start rev limiter 4200 rpm
Transmission
\ Transmission Front-wheel drive
\ Gearbox 6 speed sequential
\ Differential LSD with external preload adjustment
\ Clutch 2 plate cerametallic race clutch
\ Shift control Paddle-shift 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 adjustable in height, toe and camber
\ Front brakes 6-piston callipers, 378 mm steel ventilated discs
\ Rear brakes 272 mm steel discs
\ Brake pedal Unitary with brake balance regulation
\ Hand brake Hydraulic with mechanical locking
\ Steering system Full electrical power steering rack
\ Rims Seat Sport 10”x18”
\ ABS Removed
Body and aerodynamics
\ Roll-cage FIA homologated
\ Weight 1.145 kg
\ Front width (max) 1.950 mm
\ Rear width (max) 1.950 mm
\ Length 4.547 mm
\ Wheel base 2.665 mm
Car check-control
\ Acquisition system AIM - MXG 60 channels
\ Diagnostics Auto-diagnosis OBDII / DiagRA –LE
\ Airjack Complete car kit
\ Firer extinguishing system OMP CESAL 2

5
Dimensions and weight1.2
Dimensions
Measurements
Remarks
Overall length
4547 mm
Overall bodywork front width
1950 mm
Overall bodywork rear width
1950 mm
Wheel base
2665 mm
Over hang front splitter
897 mm
Over hang front bumper
867 mm
Over hang rear
825 mm
Over hang rear wing
160 mm
From the wing to the bumper
Minimum ground clearance
-
80 mm according to TCR regulations
Weight
Measurements
Total weight in race conditions without fuel
1145 kg **
Car balance
62% front / 38% rear
Distribution weight/power
3,47 kg/HP
Notes:
* Measured from the rear bumper to the end of rear wing profile.
** The scrutineering dimensions and minimum weight are the ones on the SEAT Leon Cup Racer TCR
Technical Form.

6
Body-shell1.3
Part number
Description
Material
01
Bonnet
Steel
02
Left / right front door
Steel
03
Left / right rear door
Steel
04
Roof
Steel
05
Boot lid
Steel
10
Bumper air duct
Plastic
11
Bonnet opening
Carbon
12
Front splitter
Carbon
13
Fender air exit
Carbon
14
Front bumper
Fiberglass
15
Rear bumper
Fiberglass
16
Left / right side trim
Carbon, Kevlar & Fiberglass
17
Left / right rear door extension
Carbon (painted)
18
Left / right rear fender extension
Carbon (painted)
19
Left / right front fender
Carbon (painted)
20
Diffuser
Carbon
21
Windscreen
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

7
Powertrain1.4
Engine features
Description
Type
2,0 TSI / Turbocharged & direct injection
Engine identification
CJX
Cylinder capacity
1984 cm3
Corrected cylinder capacity
1984x1,7 = 3372,8 cm3
Maximum power
242 kW (330 HP) at 6250 rpm
Maximum torque
410 Nm at 2000 to 5000 rpm
Maximum rpm
6800 rpm
Specific power
165 HP/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
Twin-end racing catalysed FIA Homologated / 114 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 curve:
Fuel tank features
Description
Fuel tank type
FIA FT3 homologated fuel tank
Capacity
104 l ±2%
Minimum fuel level before engine fault
Less than 1 litre
Ventilation valve
FIA homologated roll-over, ventilation and 200 mbar pressure
regulator valve
Refuelling
Safety FIA plug

8
Gearbox features
Description
Transmission
Front-wheel drive
Gearbox
6 speed sequential
Differential
LSD with external preload adjustment
Clutch
2 plate cerametallic race clutch
Shift control
Paddle-shift on steering wheel
Gearbox electronic control unit
GCU placed on EM-Box
Gearbox actuator
Monobloc electromagnetic actuator
Cooling system
Gearbox oil radiator
Downshift over-rev protection
Electronically activated
Gear ratios
Final drive
15
57
0,263
GEAR
Z1
Z2
Gear
relation
Total
relation
RPM
3000
GEAR SHIFT
6500
CUT
6800
DIF
RPM
1
12
28
0,429
0,113
42
90
94
2
13
23
0,565
0,149
55
119
124
1644
3
22
31
0,710
0,187
69
149
156
1384
4
21
24
0,875
0,230
85
184
192
1285
5
26
25
1,040
0,274
101
219
229
1079
6
29
24
1,208
0,318
117
254
266
947
Gear ratios:
Suspension features
Description
Remarks
Front damper Bilstein
2 way adjustable / Aluminium body
Clicks: 10 bump / 10 rebound
Eibach springs front and rear
160/60/70-80-90-100-110-120
Adjustable
Front antiroll-bar
22x2 // 22x3
Adjustable in 6 positions
Rear bumper Bilstein
2 way adjustable / Aluminium body
Clicks: 10 bump / 10 rebound
Rear antiroll-bar
22x3 // 22x4
Adjustable in 6 positions
Front and rear tenders
75/60/2
0
1000
2000
3000
4000
5000
6000
7000
020 40 60 80 100 120 140 160 180 200 220 240 260 280 300

9
Brake features
Description
Remarks
Front calliper
AP Racing Monobloc 6 pistons
Special: SEAT Sport
Front disc
378x34
Special: SEAT Sport
Front pump
AP Racing 19,1 mm
Front pads
Pagid 5F6 (RST03)
Orange // Thick: 25 mm
Rear calliper
AP Racing 2 pistons
Rear disc
272x10
Solid
Rear pump
AP Racing 22,2 mm
Rear pads
Pagid 5F6 (RS 4-4)
Orange
Rear press reducer
Pressure limiting valve 25 bar
Rear press reducer (power part)
AP Racing 7 position lever
Not standard
Brake balance
Mechanical
Hand brake features
Description
Remarks
Hand brake
Hydraulic with mechanical locking
Acting on rear axle
Brake pump
AP Racing 15 mm
Connection type
In series with rear brake line
Wheels1.5
Wheel features
Description
Rim dimension
10”x18” 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
GCU
Skynam
Motorsport
Engine bay (EM-Box)
Gearbox actuator
XAP
Motorsport
Engine bay
Low fuel pump control
PWM control module
Series
Roll-cage
Fuel level display
SEAT Sport
Motorsport
Cockpit
Electronic steering rack
VW
Motorsport
Front subframe
ABS/ESP unit
Continental
Not 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
Engine bay
Modules based in series
Engine ECU
Low fuel pump
Steering rack
ABS/ESP
Gateway
Specific software/mapping:
Yes
No
Yes
No
Yes
Specific codifications:
Yes
No
Yes
Yes
Yes
Interchangeable between cars:
Yes
Yes
Yes
Yes
Yes
Spare part ready for plug and play:
Yes
Yes
Yes
Yes
Yes
Modification allowed:
No
No
No
No
No
Notes:
Use always spare parts from SEAT Sport. Although the mentioned parts derive from series cars,
the software and codifications are different and modified by SEAT Sport.
All series modules used on the car are based in the MQB platform. Through the diagnostic tools
available on the VW Group dealers, it is possible to diagnostic any malfunction.

10
2 DRIVER CONTROL
In this section, it is explained how the driver can handle the different commands and functions of the car.
Main panel2.1
Function
Remarks
Ignition switch:
It activates the power to all devices. The Main Switch has to be active.
Main switch:
It activates the power supply.
Lights switch:
It activates the low beam. High beam and flash activation buttons are placed on
the steering wheel module.
Turn indicator:
It activates the left and right turn lights. A green alarm on the display appears
showing that the turn light is blinking.
Brake balance:
Turning the balance wheel you can balance the brake pressure from front to
back or vice versa.
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.
Notes:
To start the car, always proceed in this order: Main switch and later ignition switch.
The correct procedure to stop the car is the following:
1. Stop the engine using only the yellow switch (ignition switch/KL-15).
2. Wait at least 60 seconds. If the waiting time is lower, the OBD faults memory is not saved.
3. Switch off the car using the red switch (main switch/KL-30).
If this procedure is followed correctly the OBD faults memory is saved and these faults can be
checked with the diagnostics tools at any time thereafter. These faults are saved until the memory
is deleted manually using the diagnostics program.
The diagnostics tool DiagRA-LE is recommended for customers to be able to check the cars.
Steering wheel module2.2
The electronic steering wheel module permits
activating different functions without removing hands
from the steering wheel.
Some buttons have double functionality.
Main switch
Ignition switch
Lights switch
Turn indicator
Brake balance