Seat Leon Cup Racer TCR 2016 User Manual
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Seat Leon Cup Racer TCR 2016 User Manual

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  • Page 2: Table Of Contents

    INDEX TECHNICAL INFORMATION ................... 4 SEAT Leon Cup Racer TCR display ............... 4 Dimensions and weight....................5 Body-shell ........................6 Powertrain ........................7 Wheels ......................... 9 Electronic units ......................9 DRIVER CONTROL ......................10 Main panel ......................... 10 Steering wheel module .................... 10 Display alarms and shift lights ................
  • Page 3 Brakes ........................33 4.10 Aero ..........................33 WORKSHOP MAINTENANCE ..................34 First roll-out ........................ 34 Check-list ........................34 Body-shell and engine identification ..............35 Fluids .......................... 36 Engine ........................36 Air filter ........................37 SADEV ST82-17 gearbox ..................38 LSD – Limited Slip Differential ................38 Fuel tank ........................

  • Page 4: Technical Information

    TECHNICAL INFORMATION SEAT Leon Cup Racer TCR display Engine \ Type Turbocharged; 4-cylinder in line \ Fuel supply system Direct fuel injection \ Cylinder capacity 1984 cm \ Bore and stroke 82,5 mm x 92,8 mm \ Maximum power 330 HP / 6250 rpm...

  • Page 5: Dimensions And Weight

    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.

  • Page 6: Body-Shell

    Body-shell Part number Description Material Bonnet Steel Left / right front door Steel Left / right rear door Steel Roof Steel Boot lid Steel Bumper air duct Plastic Bonnet opening Carbon Front splitter Carbon Fender air exit Carbon Front bumper Fiberglass Rear bumper Fiberglass...

  • Page 7: Powertrain

    Powertrain Engine features Description Type 2,0 TSI / Turbocharged & direct injection Engine identification Cylinder capacity 1984 cm Corrected cylinder capacity 1984x1,7 = 3372,8 cm Maximum power 242 kW (330 HP) at 6250 rpm Maximum torque 410 Nm at 2000 to 5000 rpm Maximum rpm 6800 rpm Specific power...
  • Page 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...

  • Page 9: Wheels

    Modification allowed: 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...

  • Page 10: Driver Control

    DRIVER CONTROL In this section, it is explained how the driver can handle the different commands and functions of the car. Main panel Ignition switch Lights switch Main switch Turn indicator Brake balance 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.

  • Page 11: Display Alarms And Shift Lights

     LED 2 red alarm light + POP UP: Very low oil pressure. Big risk to break the turbo or to damage the engine. Seat Sport recommends slowing down and entering to the pit-lane or stopping in a safe place.
  • Page 12 Some torque reductions will appear but you can continue.  LED 6 red alarm + POP-UP message: Critical water temperature. Seat Sport recommends slowing down and entering to the pit-lane or stopping in a safe place, to avoid damaging the engine.

  • Page 13: Gearbox Functioning

    This system is automatically and only activated if wheels are absolutely stopped. The throttle pedal can be fully pressed and engine speed will be limited at 4200 rpm until the car starts moving. There are many ways to manage standing starts; following the SEAT Sport recommendation is explained. Process: After the grid formation lap, stop completely the car on the grid line pushing clutch and brake pedals.

  • Page 14: Speed Limiter (Virtual Safety Car)

     Take care of the time you are keeping the engine preloaded at 4200 rpm. The clutch and the engine may take temperature very fast. Recommendation no more than 6 seconds of start rev limiter use. Speed limiter (Virtual Safety Car) The speed limiter system allows limiting the car speed at a predefined value.

  • Page 15: Electronics

    ELECTRONICS AIM MXG MXG is the AIM dash-logger designed to acquire and display data coming from your ECU, the internal accelerometer and gyro, as well as from the GPS module, analog/digital inputs and predefined math channels. Performance and data acquired can also be incremented adding expansion modules. To enable “the lap time”...

  • Page 16: Mxg Connection Schemes

    Shift lights and alarms: On the top of the display there are ten gear flash leds that can be freely configured. The rpm value at which to turn it on and the colour can be defined. Gear dependent lights can be also defined.

  • Page 17: Data Acquisition

    Channel expansion module and sensors are available through AIM dealers, not SEAT Sport.  If for any reason it is necessary to send data acquisition files to SEAT Sport, following data file extensions must be sent: .drk, .bak, .gpk, .rrk and .xrk.
  • Page 18 8 … 15 External Voltage Battery Voltage 0 … 100 P_GCU_CLUTCH Clutch pressure -1 … 7 POS_GCU_GEAR Gear 80 … 150 T_GCU_OIL Gearbox oil temperature º 0 … 5000 U_GCU_GEAR Gearbox potentiometer 0 … 32767 POS_XAP_POT Actuator position 0 … 32767 POS_XAP_POT_FILT Actuator position filtered 8 …...

  • Page 19: Fusebox

    Internally, the thermal fuses reset automatically, so changing a fuse will never be necessary. In case of malfunction it has to be sent to SEAT Sport. It is also possible to check if a fuse has blown in the fusebox, so you will know if the current or signal was sent.
  • Page 20 bit3 --3----- Gear Lever / GCU bit2 -2------ Diagnosis Connector bit1 1------- Power steering ECU bit8 -------8 bit7 ------7- Front Fan bit6 -----6-- bit5 ----5--- Blackbox / Gateway FLAG_FBX_F3 bit4 ---4---- Differential bit3 --3----- +30 Aux. connector bit2 -2------ bit1 1------- ABS ELV bit8...

  • Page 21: Fuel Level Display

    Fuel level display All new SEAT Leon TCR cars have a fuel display to control the fuel remaining at the tank. It is tied to the roll cage in the rear right door area. The display has to be set after each refuelling. This setting is very important to get the correct fuel level because it is calculated by the fuel consumption sent from the engine ECU.

  • Page 22: Auxiliary Connectors

    Set Full level value: This menu allows setting the maximum tank level or predefined fuel level. Brightness and bar graph set: It is possible modify the brightness and bar graph settings. Long left push will scroll menu on the other side. “Auto”...
  • Page 23 FS 2,8 x 0,8 (*) Radio and drink Behind the driver seat there are two free connectors associated with the steering wheel module. Connecting here the radio and drinking systems, both can be handled through the steering wheel module. Radio connector...
  • Page 24 Power supply cut: There is a connector that gives power supply to the fusebox, so in case of disconnection cuts all devices power supply. You can unplug it in case of transport or for a most safety disconnection in case of workshop big jobs. See connector placement close to the fusebox main connectors on the picture beside.

  • Page 25: Setting Adjustments

    SETTING ADJUSTMENTS Standard set-up Note:  This is also the car delivery set-up. Due to production issues, small changes on this set-up sheet may occur. Seat Sport recommends doing your own check.

  • Page 26: Steering Rack Centering

    Steering rack centering As the steering rack is electric, the steering angle sensor has to be electronically aligned with the wheels at the aligning time. How to proceed to align the steering angle sensor: It is necessary fix the steering wheel. To do it, you can use straps fixed between the roll cage and the steering wheel or other kind of standard tools.

  • Page 27: Rear Camber And Toe Adjustments

    Front regulation table: Wishbone regulation Camber Toe regulation 1,5 turns = 10’ camber -5.8º 9,5 turns 12 turns -5,5º 7 turns 8,3 turns -5º 3,5 turns 4,5 turns -4,5º -4º -3,5 turns -4 turns -3,8º -6 turns -7 turns -5.8º 9,5 turns 12 turns Note:...

  • Page 28: Dampers

    Dampers Front dampers 2-way adjustable with 10 clicks in bump and 10 in rebound Aluminium outer housing 20 mm bump stop (5000 N / 4 mm) Note:  Clicks adjuster tool delivered with the car.
  • Page 29 Rear dampers 2-way adjustable with 10 clicks in bump and 10 in rebound Aluminium outer housing 35 mm bump stop (5000 N / 4 mm) To set-up the suspension, the following spring range can be used in both front and rear axles: Springs Remark 160-60-120...

  • Page 30: Anti-Roll Bars

    Adjustment range of front dampers: Adjustment range of rear dampers: Anti-roll bars Two front anti-roll bars available: 22x2 and 22x3. Car delivery: 22x3. FRONT ARB OD (mm) Thickness (mm) Chassis Roll Stiffness from ARB Hard (Nm/ºChassis) 1548 2021 Mid (Nm/ºChassis) 1293 Soft (Nm/ºChassis) Two rear anti-roll bars available: 22x3 and 22x4.

  • Page 31: Kinematics

    Kinematics FRONT...
  • Page 32 REAR...

  • Page 33: Brakes

    Brakes To set-up the brakes, the following pumps can be used in both axles: Master cylinder 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 AP 19,1 MM PRT 110 Car delivery front AP 20,6 MM...

  • Page 34: Workshop Maintenance

    WORKSHOP MAINTENANCE First roll-out SEAT Sport checks all the cars in a roll-out before customer delivery. This roll-out consists in:  5 circuit laps.  High speed in a long straight.  Start rev limiter checking simulating a standing start.

  • Page 35: Body-Shell And Engine Identification

    Body-shell and engine identification V.I.N. (Vehicle Identification Number) is welded on the roll cage. Engine number XXXXXX Engine seals: boost, distribution and oil sump...

  • Page 36: Fluids

     Change the engine oil and oil filter at the indicated mileage.  Engine spare parts must be from VW group or SEAT Sport original parts, detailed on the SEAT Leon Cup Racer TCR parts catalogue.  Use always the fluids detailed above, User Manual point 5.4.

  • Page 37: Air Filter

    Air filter Standard air filter cleaning procedure: Parts subject to frequent service: Air filter Torque Remarks Substitution By hand Be careful tightening the small bolts over plastic Cleaning Clean the cotton air filter following the procedure shown above. Do not use compressed air or high-pressure air to clean.

  • Page 38: Sadev St82-17 Gearbox

    Change the gearbox oil and clean the filter in the indicated mileage. The oil must be the recommended one. It can be done with the gearbox mounted on the car.  It is strongly recommended reading the SADEV ST82-17 Technical Manual on the SEAT Sport website. http://www.seat-sport.com/seat-leon-cup-racer-2016/ ...

  • Page 39: Fuel Tank

    Different ramps are available on SADEV Parts Catalogue. Only the ramps homologated on the SEAT Leon Cup Racer TCR Technical Form can be used.  For detailed information see the SADEV ST82-17 Technical Manual on the SEAT Sport website: http://www.seat-sport.com/seat-leon-cup-racer-2016/ Fuel tank The new 100l FIA FT3 fuel tank is working with one unique fuel pump coming from series and a complex Venturi hoses system.
  • Page 40 There are two tools available on the 2016 Parts Catalogue. First, there is a contra-connector D-6 socket available to connect in the fuel line plug that opens the circuit for draining. Secondly, SEAT Sport has developed a new electronic tool to activate the fuel tank pump permanently or with the new automatic function.
  • Page 41 Fuel draining process: Connect the electric tool on the fuel pump connector (#2 on the picture above), placed on the fuel tank, and the power supply on the auxiliary battery connector (#3). Connect the fuel socked connector on the engine bay. Switch on the electric tool in automatic or manual mode.

  • Page 42: Airjacks

    Engine fuel filter placement inside the fuel cell: 5.10 Airjacks The SEAT Leon Cup Racer TCR is provided with an airjack system. The connector is placed on the rear right side (inside the standard refuelling cover). Airjack plug on the car:...
  • Page 43  IMPORTANT: never work under a vehicle supported only by airjacks unless safety props are fitted.  Do not use 'U' bolt type clamps as distortion of the body will cause the airjack to stick. Do not loosen or remove adaptor. Jacks must be vertical during operation. Mounting brackets or clamps to be fitted to threaded section of body only.

  • Page 44: Parts Mileage

    10.000 Change when noise Rear discs 1.500 Wheel nuts 3.000 Safety parts Service / km Change Remark Extinguisher 5 years 7 years SEAT Sport or OMP service Backet 5 years Safety belts 5 years Fuel cell 5 years 7 years...

  • Page 45: Safety

    SAFETY Part Remarks Images 3 airjacks on the car Airjack Max pressure 30 bar Safety props: for any job under the car use always airjack safety props (x3). Material: aluminium. Extinguisher Weight: 6,2 kg. Activation: electric. Use: cockpit and engine bay. Check the inner press bottle.

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