Seat New Leon Cupra 2008 User manual

2008 SEAT Sport UK
Technical Manual – New Leon Cupra

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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2008 SEAT Sport UK
Technical Manual – New Leon Cupra
CONTENTS
Section Title Page
1 Introduction 2
2 General 3
3 Safety Requirements 13
4 General Technical Requirements 14
5 Chassis 15
6 Bodywork 20
7 Engine 24
8 Suspension 35
9 Transmission 45
10 Electronics 50
11 Brakes 54
12 Wheels and Steering 56
13 Tyres 57
14 Weight 58
15 Fuel 59
16 Silencing 60
Appendix A Engine Return Checklist
Appendix B Gearbox Return Checklist
Appendix C Loan Engine Contract 65
Appendix D Loan Transmission Contract 67

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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1. Introduction: (5.1)
The following document (2008 SEAT Sport UK, Technical Manual – New Leon Cupra) is to be viewed as a
technical reference in conjunction with the 2008 SEAT Cupra Championship Regulations. All
measurements and restraints are to be as listed and referenced from an Official SEAT Sport UK Reference
Specification Car and/or parts.
For ease of use and where possible, the manual is set out in accordance with the MSA specified format, to
correspond with the 2008 SEAT Cupra Championship Regulations. It should be understood that where a
Regulation is included this is for ease of reference and does not indicate that the entry only refers to that
particular Regulation. For the avoidance of doubt, a breach of the Technical Manual may be regarded as a
breach of the Technical Regulations and treated as such.

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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2. General: (5.2)
Steering Type: Rack and pinion with power assistance
Front Suspension: Independent McPherson strut with anti-roll bar
Rear Suspension: Independent multiple arm with anti-roll bar
Shock Absorber: Koni 2-way adjustable
Rims: 8” x 18” / 8.5” x 18”
Front calliper: 6 pistons
Front brake disc: 362 x 32 mm
Rear brake disc: 255 x 10 mm
Brake distribution: Adjustable from the cockpit
Master cylinders (standard): 19 mm (0.75”) front and 22.2 mm (7/8”) rear
Adjustments: Front and rear camber
Front and rear toe
Front and rear ride height
Anti-roll bars
Springs
Dampers
Tyre pressures
Rear wing angle
Brake Master Cylinders
Chassis
Wheel Base: 2596mm between axle centre lines
Front Track: 1915mm max.
Rear Track: 1810mm max.
Body Height: 1390mm max.
Body Width: 1915mm (without rear view mirrors).
Body Length: 4485mm max.
Vehicle Weight
With Competitor: 1250kg min.
Minus Comp. & Comp. ballast: 1155kg min.
Table of Capacities
Engine Oil: 4.5 lts (Oil type and manufacture .T.B.C.)
Gearbox Oil: 7.2 lts. V.A.G G052182A2 Direct Shift Gearbox oil.
4.5 – 5.0 lts. Gearbox Oil change capacity (see page 48)
Fuel Tank: 65 lts.
Coolant: 7 lts.
Screen wash: Screen wash level is free

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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Timing Module Transponder: (3.15.1)
Timing Modules shall remain as fitted inside the front right hand wheel arch shown in diagram 1.
Model No. AMB TRANX 260 DP.
Diagram 1
Vehicle Geometry:
REFERENCE MIN MAX
Front Track Free within adjustments 1915mm
Rear Track Free within adjustments 1810mm
Front Camber Free within adjustments 3.5 Degrees negative
Rear Camber Free within adjustments 3.5 Degrees negative
Front Ride Height 55mm Free within adjustments
Rear Ride Height 55mm Free within adjustments
Front Castor Fixed Fixed
Rear Castor Fixed Fixed
Front Toe Free within adjustments Max Car Width
Rear Toe Free within adjustments Max Car Width
Tyre Pressures 1.6 Bar cold Free
Dampers See section 8 See section 8
Rear Wing A1 C5
Spring Rate Front 160-60-130 / 160-60- 110 / 160-60-90 / 250-60-70
Spring Rate Rear 160-60-80 / 160-60-70 / 160-60-60 / 160-60-50

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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Tightening Torques
This table shows the standard tightening torques. These are recommended values which a bolt of this type
should be tightened to. These tightening torques are for steel on steel. For aluminium or on heli-coil, the
torque should be lower. Bolts fitted into heli-coils should be installed with Coppaslip/anti-seize
compound.
Please note that the torque values detailed in this manual are for fitting purposes only. Do not check at
these torques. The table gives the dry and lubricated tightening torques. Common, medium-viscosity
grease has been used as a reference.
ISO PROFILES Dry Lubricated
Metric 8.8 10.9 12.9 8.8 10.9 12.9
Quality Thread Torque lb ft Torque lb ft
4 0.70 3.1 4.3 5.2 2.1 2.9 3.5
5 0.80 6.2 8.8 10.5 4.1 5.8 7.0
6 1.00 10.6 14.9 17.9 7.1 9.9 11.9
8 1.25 25.8 36.2 43.5 17.1 24.0 28.8
9 1.25 38.1 53.5 64.2 25.0 35.1 42.2
10 1.00 56.5 79.4 95.3 36.3 51.0 61.3
10 1.25 53.7 75.6 90.7 35.0 49.2 59.1
10 1.50 51.0 71.7 86.1 33.7 47.4 56.8
12 1.50 92.9 130.6 156.7 60.5 85.1 102.1
12 1.75 88.9 125.1 150.1 58.6 82.4 98.9
14 2.00 142.1 199.8 239.8 93.5 131.4 157.7
16 2.00 220.1 309.6 371.5 143.4 201.7 242.0
18 2.00 322.3 453.2 543.8 208.4 293.1 351.7
20 2.50 429.9 604.6 725.5 280.1 393.9 472.7
22 2.50 585.5 823.3 988.0 379.1 533.2 639.8
The standard tightening torque table should be used for bolts that have not been specifically indicated in
this manual.
Specific Torques and common fixings are show in the following table and diagrams:
Description Torque Note
Wheel nut 110 Nm Coppaslip grease
External Drive shaft Tighten to 240 Nm loosen 1 turn
Tighten to 240 Nm +90º Replace bolt after 2 installations
Internal Drive shaft 80 Nm Coppaslip grease
Track rod end to adjuster 60 Nm 648 loctite
Front damper to wheel hub 80 Nm Coppaslip grease
Front damper top mount 70 Nm Coppaslip grease
Rear damper to wheel hub 35 Nm Coppaslip grease
Rear wheel bearing central bolt 300 Nm Replace bolt after 2 installations

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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Service/Inspection Recommendations:
Description Part Number Km check Km life Remarks
Engine Assembly VLH1100010 Season N/A Rebuild SEAT Sport UK
Throttle Butterfly 06F133062G Every event 2000 Visual check
Spark Plugs 101905631B N/A 2 events Gap set at 0.8mm
Engine Oil NSCAS0W40 N/A 1 event 4.5 lts
Engine Oil Filter 06D115562 N/A 1 event SEAT Sport UK
Air Filter Element V4PL133838 1 event N/A Oil after washing
Boost Control Solenoid 06F906283F N/A 2000 Engine rebuild
Accelerator Module Unit 1K1721503L N/A Season SEAT Sport UK
Auxiliary Water Pump 1K0965561G N/A Season SEAT Sport UK
Lambda Probe 06F906262AC N/A 3000 SEAT Sport UK
Flywheel V4PL105273 2 event 3000 Check rotational play
max : 4 teeth = 8˚
Fuel Filter 1K0201051C N/A 2 events SEAT Sport UK
Low Pressure Fuel Pump V4PL919085 1500 3000 Check pre-filter
Additional Fuel Lift
Pump 35906092C 1500 3000 Check pre-filter
Gearbox Assembly VL1E300C00 3000 N/A SEAT Sport UK
Gearbox Support V4PL199555A 500 N/A Visual check
Gearbox Oil G052182A2 N/A 1000 See transmission section 9
Drive Shaft Assembly V4PL407271B Every event
Std grease
300k
Neo grease
600k
Strip, clean, repack with
grease 125 grams
Front Roll Bar V4PL411303 Every event N/A Horizontal Checking/Clean
and Lubricate
Rear Roll Bar V4PL511407 Every event N/A Horizontal Checking/Clean
and Lubricate
Front Upright Assembly V4PL407251 500 N/A Visual check and crack test
Front Upright Bearing 1K0407621C 300 Re grease
1000k Check free play
Rear Upright Bearing 1T0501611E 600 Re grease
2000k Check free play
Front Wishbone
Spherical Joints NSSCC407502 500 6000 Check free play
Rear Arm Joints V4PL50167 3 / 4 2000 N/A Check free play
Front Wishbone
Bushing V4PL407186A 500 3000 Check free play
Front Damper V4PL413031 1000 N/A Dyno at SEAT Sport UK
Rear Damper V4PL513025 1000 N/A Dyno at SEAT Sport UK
Front Damper Spherical
Joint SSV2ML407502A 500 6000 Check free play

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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Description Part Number Km check Km life Remarks
Front Damper Friction
Washer SSV2ML412145 N/A 6000 N/A
Steering Rack IML422061 1000 10000 Free Play and Hard Points
Steering Rod Joint LH = 1K0423811F
RH = 1K0423812F 1000 N/A Check free play
Steering Arm V4PL407725 1000 N/A Visual check
Front Brake Calliper LH =V4PL615105
RH =V4PL615106 300 N/A Inspect seal condition
Brake Master Cylinder
NSMAR1210BF95 = 17.8
NSMAR1220BF95 = 19.1
NSMAR1230BF95 = 20.6
NSMAR1240BF95 = 22.2
N/A 3000
Alternator 06F903023B N/A 3000 SEAT Sport UK
Starter N/A 6000 SEAT Sport UK
Battery NSDTV2 N/A 3000 Maintaining 12v
Fire Extinguisher MFE400AKIT 2 years N/A Following MSA/FIA Control
Intercooler Pipes All Every
session N/A Visual/Pressure check
Intercooler 1K0145803A Every event N/A Visual/Pressure check
Front Brake Discs LH/V4PL615297
RH/V4PL615298 Every event N/A Check for cracks and free play in bells
Power Steering Hoses All 500 season Visual check

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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3 Safety Requirements: (5.3)
Seat (5.3.2)
Replacement of the driver’s seat must comply with Regulation 5.3.2.1.
Seat Mounting Brackets (5.3.2.2)
Whilst installing the seat, note the clearance of the lap strap holes in the side of the seat.
Replacement of the seat mounting brackets must comply with regulation 5.3.2.2.
Internal Rear View Mirror (5.3.6.3)
The single internal rear view mirror original supplied by SEAT Sport UK, (shown in diagram 2) may be
replaced with an optional mirror kit, SEAT Sport UK Part No.NS225MK-1 (shown in diagram 3) the fitting,
location and orientation of either mirror must be as show in diagrams 2 or 3. It is not permitted to fit any
other internal mirror.
Diagram 2 – Standard size internal mirror
Diagram 3 – SEAT Sport UK convex wide mirror

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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4 General Technical Requirements: (5.4)
Fixings (5.4.5)
Fixings specification must remain as those supplied by SEAT Sport UK.
Heat Insulation (5.4.7)
Heat insulation specification must remain as those supplied by SEAT Sport UK.
SEAT Sport UK Base Set Up for the New Leon Cupra Race Car
At the point of collection all cars will have the following base set up:
Toe
Front Toe: 15’ out each wheel
Rear Toe: 15’ out each wheel
Camber
Front Camber: -3.5˚
Rear Camber: -3.0˚
Roll Bars
Front Roll bar: Middle Position
Rear Roll bar: Middle Position
Dampers
Front compression: Centre Position
Rear compression: Centre Position
Front Rebound: Centre Position
Rear Rebound: Centre Position
Springs
Front: 160/60/90 main 60/60/2 helper
Rear: 160/60/60 main 60/60/2 helper
Rear Wing
Rear Wing Position: B2 = 0˚
Brake Bias
Front/Rear Brake Bias: 50/50 %

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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5Chassis: (5.5)
Each car will be fitted with a Chassis SEAT Sport UK Conformation Seal. The SEAT Sport UK Conformation
Seal is placed on the roll cage centre cross brace. This seal must not be altered or interfered with in any
way.
Chassis SEAT Sport UK Confirmation Seal is shown in diagram 4.
Diagram 4
Tyre to Chassis Clearance
To allow extra clearance for the front tyres, the shaded area marked below in diagram 5 may be folded in at
a 90˚angle towards the strut tower. The diagram shows the right hand side of the car, but the same is true
of the left hand side. No other modifications are permitted. For further information, please contact the SCC
Technical Manager.
Diagram 5

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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To allow extra clearance for the rear tyres, the orange shaded area marked below in diagram 6 may be
folded outward so that it is flat to the rest of the inner rear wheel arch. The diagram shows the left hand
side of the car, but the same is true of the right hand side. No other modifications are permitted. For
further information, please contact the SCC Technical Manager.
Diagram 6

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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Rear Wheel Arch Liner
To reduce debris collecting on top of the flat floor, a wheel arch liner kit shown in diagram 7 (marked A with
fixings marked B), is available from SEAT Sport UK, Part No .NSRA1KIT
The fitting of this kit is optional.
Diagram 7

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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Rear Tow Strap-Mounting Point
The mounting point for the rear tow strap may be modified to reinforce the area. Only the exact
modifications detailed below are authorised. For further information, please contact the SCC Technical
Manager.
Diagram 8 shows four points where the reinforcing plate may be drilled and then connected to the plate
behind using rosette welds.
Diagram 8
Diagram 9 and 10 detail seven points where stitch welds may be used to reinforce the chassis to the rear
panel. No other welding or bolting is authorised.
Diagram9 Diagram10

2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
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Roof Vent Aperture (5.5.1.3)
Cars with the SEAT Sport roof vent aperture shown in diagram 11, are required to have roof vent cover SEAT
Sport UK Part No. NSSCC 070061 (diagram 12) fitted.
Diagram 11
Diagram 12