User Manual

Leon Super Cup Mk 2









2009 – VERSION 1.0



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USER MANUAL LEON Mk2 2009






The SEAT Leon Super Cup Mk2 is a racing car developed by SEAT Sport, based
on the new SEAT Leon, which continues the successful SUPERCOPA
championship launched by SEAT in 2002.




The main technological innovations developed by SEAT sport for the new SEAT
Leon Super Cup Mk2 are:

His direct injection turbo engine is the first time that’s used in a manufacturer
cup.
Also for the first time his in a manufacturer cup his new DSG gearbox, tuned by
SEAT Sport for racing purpose.
Development of an aerodynamic package, with ground effect to increase the
down force.






With the new León Super Cup Mk2, SEAT Sport substantially improves the
performance of the previous Leon Super Cup, maintaining its commitment to
costs and reliability for his customers, strengthening the Cup school spirit and
bringing the performance of the car to the higher ranks of touring cars.
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USER MANUAL LEON Mk2 2009

Introduction.
This user manual is intended as a helpful guide for the tune-up and service of the
Leon Super Cup manufactured by SEAT Sport S.A.

If you have any doubts, enquiries or suggestions, please contact the championship
organiser and the car manufacturer:


SEAT SPORT, S.A.
AVDA.CAN AMAT, 7
E-08630 ABRERA
BARCELONA - SPAIN
http://seat-sport.seat.es


Technical representative:
Antonio Almirall
Tel. +34 93 774 45 54
Fax. +34 93 773 3108
Antonio.almirall@seat-sport.com


Commercial representative:
Xavier Carrasquilla
Tel. +34 93 774 4531
Fax: +34 93 773 3410
javier.carrasquilla@seat-sprt


Spares:
Laura Brullas
Tel. +34 93 773 3399
Fax: +34 93 773 3410
laura.brullas@seat-sport.com




For other doubts or questions, please contact the commercial representative, who
will notify the representatives of the different areas.
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USER MANUAL LEON Mk2 2009
CONTENTS:
1 GENERAL SPECIFICATIONS .................................................................................. 6
1.1
Engine ...............................................................................................................7
1.1.1
Turbo compressor ...............................................................................................7
1.1.2
Fuel supply system..............................................................................................8
1.1.3
Cooling ..................................................................................................................9
1.2
Transmission .................................................................................................11
1.2.1
Gearbox mode module.......................................................................................11
1.2.2
Launch control: ..................................................................................................13
1.2.3
Technical features of the DSG gearbox ........................................................13
1.3
Electronics .....................................................................................................14
1.3.1
CAN-Bus ..............................................................................................................14
1.3.2
Dashboard ..........................................................................................................17
1.3.3
Data logger .........................................................................................................19
1.3.4
Driver console ....................................................................................................22
1.4 Brake ...............................................................................................................23
1.5
Chassis ...........................................................................................................24
1.6
Body shell ......................................................................................................25
2 FINE-TUNING......................................................................................................... 27
2.1
Tyre information............................................................................................27
2.2
Recommended car set-up...........................................................................27
2.3
Front axle adjustments................................................................................28
2.3.1
Adjustments of the suspension geometry ...................................................28
2.3.2
Steering ...............................................................................................................33
2.3.3
Front springs ......................................................................................................35
2.3.4
Ground clearance..............................................................................................35
2.3.5
Anti-Roll Bar .......................................................................................................38
2.3.6
Front shock absorbers......................................................................................39
2.4
Adjustments to the rear axle......................................................................41
2.4.1
Adjustments in the suspension geometry. ..................................................42
2.4.2
Springs. ...............................................................................................................44
2.4.3
Ground clearance..............................................................................................45
2.4.4
Rear anti-roll bar ...............................................................................................45
2.4.5
Rear shock absorbers.......................................................................................46
2.5
Brakes.............................................................................................................47
2.5.1
Brake balance ....................................................................................................47
2.5.2
Brake fluid...........................................................................................................49
2.5.3
Pumps..................................................................................................................50
2.6
Aerodynamics................................................................................................50
2.6.1
Front spoiler .......................................................................................................50
2.6.2
Rear wing ............................................................................................................50
2.6.3
Pitch angle ..........................................................................................................53
3 MAINTENANCE AND SERVICE ............................................................................ 56
3.1
Engine .............................................................................................................56
3.1.1
Fuel system .........................................................................................................56
3.1.2
Turbo....................................................................................................................56
3.2
Gearbox ..........................................................................................................60
3.2.1
Mecatrónica. .......................................................................................................61
3.3
Suspension....................................................................................................63
3.3.1
Front suspension ...............................................................................................63
3.3.2
Rear suspension ................................................................................................63
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USER MANUAL LEON Mk2 2009
3.3.3
Shock absorbers................................................................................................64
3.4
Steering ..........................................................................................................64
3.5
Brakes .............................................................................................................64
3.5.1
Running in the pads..........................................................................................64
3.6
Body shell ......................................................................................................64
3.6.1
Rebuilding ..........................................................................................................64
3.6.2
Codriver baquet fixation ...................................................................................65
3.7 Composites .....................................................................................................66
3.7.1
Case 1: Little repaires (non structural). ....................................................66
3.7.2
Case 2: Repairs with minumum structural damage...............................67
3.7.3
Case 3: Medium structural damages.........................................................68
3.7.4
Case 4: Structural repairs.............................................................................69
3.8
Electrical.........................................................................................................70
3.8.1
Recommendations ............................................................................................70
3.8.2
Diagnosis............................................................................................................70
3.8.3
Logger: ................................................................................................................70
3.8.4
VAS: .....................................................................................................................71
3.8.5
Battery .................................................................................................................74
3.8.6
Circuit-breaker/contact....................................................................................74
3.8.7
Fuel .......................................................................................................................74
3.8.8
Turbo water re-circulation pump ...................................................................75
3.8.9
Extinguisher........................................................................................................76
3.8.10 Fuses and relays................................................................................................78
3.9
Tightening Torques ......................................................................................79
3.10 Specific
Torques ............................................................................................80
3.11 Maintenance
intervals ...................................................................................87
Recommended service intervals ..........................................................................87
3.12 Capacidades de líquidos. ..............................................................................90
3.13 Air Jacks ..........................................................................................................91


















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USER MANUAL LEON Mk2 2009
1
GENERAL SPECIFICATIONS
Specifications table
Engine

Tipe
Turbo 4 cylinders
Intake system
Direct fuel injection
Capacity 1984
cc
Bore / Stroke
82,5 x 92,8
Max power
301 CV
Max torque
340 Nm
ECU
BOSCH MED 9.1
Exhaust / dB
Racing catalizator / 98dB
Fuel cell
Origial with two flor pumps


Transmision

Wheel drive
2 in the front
Gearbox DSG
6
speeds
Differential
Slip dif with discs
Gear shift
Electrical on the steering Wheel.


Xasis and Sudpension

Front suspension
McPherson, adjustable on caber, toe and high,
Rear suspension
Multi-link, adjustable on camber, toe and high
Spring
Helicoidal adjustable in high
Front brake
6 piston calliperss, disc 362 mm ventiled
Rear brake
255 mm disc ventilled
Brake pedal
Unitary with brake balance in
Steering
Hydraulic assist
Rims
SEAT Sport 9.5”x18”


Car control

ECU
Autodiagnosis VAS available
Data adquisition
AIM with 25 CAN + 8 mathematic channels


Body and aerodynamic

Roll bar
Homologated FIA and Hans adapt
Driver position
Backward to improve the weigh balance
Aerodynamic
Complete flat bottom
Splitter
Rear diffuser and wing
Front wing
Front width (max)
1.858 mm (a 6 grados de caída)
Rear width (max)
1.787 mm (a 6 grados de caída
Overall length
4.476 mm
Wheel base
2.596 mm
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USER MANUAL LEON Mk2 2009

1.1 Engine

The Super Cup engine comes from the latest-generation 2.0 l Turbo FSI by the VW
group. It’s technical specifications include the following features:
Turbo-compressor in cast on the exhaust manifold.
Monoflow exhaust system with catalyser.
High-pressure fuel pump.
No-return fuel system.
Direct injection into combustion chamber

Description
Value
Engine ID
BHZ / CDL
Type
4 cylinders – 4 valves per cylinder
Capacity 1984
cc
Bore/Stroke
82.5 x 92.8 mm
Compression
9.8:1
ratio
Maximum power 220 KW/301 HP at 6500 rpm
Maximum torque 340 Nm/2100 rpm
Intake system
Direct Fuel injection, turbo and specific
intercooler
Ignition
One Electronic coil per cilynder
Fuel
Unleaded petrol 98 octane
Generator 90
A
Battery
Dry 26 Ah/280 A

Some interest data:
o The automatic limit control is at 6800 rpm, and this it’s done by closing the
throttle. This “cut” is very light and difficult to perceive for the driver. To
check the adquisition data is recommended and to change the maximum
rpm shift light if is necessary.
o The communication with the gearbox Mecatronica is done through the
CAN-Bus line permit to control the “Start Mode system” (point 1.2.2).
o The average engine consumption is 0,46 l x km.
o To have the car on optimum conditions we recommend to follow the
“Service intervals explained in the point 3.11.

1.1.1 Turbo compressor
The turbo is placed on the back of the engine and is assembled with the
exhaust manifold. It’s made by KKK and is cooled by water.
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USER MANUAL LEON Mk2 2009

Operation:
The usual boost is 1.9 bar. The over boost control is done by a Waste Gate
controlled by the ECU. In case a over boost happens, the ECU will acct with different
strategies like close the throttle.

1.1.2 Fuel supply system

The improvements introduced in the Leon Super Cup Mk2 are:

Double side fuel tank.
Addition of a second flow pump.
Addition of a homologated 'fast connection'.

The direct fuel injection system inject directly at the combustion camera at high
pressure. This injection pressure is variable between 50 and 120 bar depending the
engine requirement.
It’s advisable to don’t run the car frequently with less than 5 litres of petrol
because the low pressure petrol pump could be damaged.
The fuel petrol system is able to empty the tank almost completely because of that,
the engine starts to misfyre when there are between 3 to 5 l remaining in the tank.
This system has to be asembled like shows the following figure 1.





The flow pumps located inside the fuel tank work via a pulsed current control
module controlled by the engine ECU giving a modulated pressure between 3 and 7
bar.
If you want to empty the fuel from the tank, consult section 4, “Maintenance",
point 4.6.5 “Fuel”.

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USER MANUAL LEON Mk2 2009

1.1.3 Cooling

The improvements introduced in the Leon Super Cup Mk2 are:

o Replacement of the standard electric fans by a double specific fitted
directly to the radiator.
o Adition of 2 adicional lateral water radiator.

To maintain the turbo cooling water recirculation system (approximately 15 minutes
after stopping with hot engine), the vehicle main battery switch should not be
disconnected.
The fan range it is beetewn 94º C to 87º C.
It’s advisable to stop the engine thru the ignition switch, never disconnect the main
switch before 15’ since the engine has been stopped. (Minimum electric
consumption)


THERMOSTAT
The Leon Super Cup Mk2 has a thermostat in the cooling system on the production
cars, The engine cooler fan range it’s between on 85°.
It’s aloud to disassemble that thermostat. To do so, you have to take off all the
mechanic parts from the inside of the plastic that contains them and it’s located at
the engine behind the generator.
the dissasembling is admitted. Whenever the elimination of the thermostat is
decided, the recirculation circuit must be obturate at the same time, (to see figure 2
“tube R”) maintaining all the tubes and the assembly position.
















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USER MANUAL LEON Mk2 2009
Main Cooling system diagram.




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