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Seat New Leon Cupra 2008 Technical Manual

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2008 SEAT Sport UK
Technical Manual – New Leon Cupra

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Summary of Contents for Seat New Leon Cupra 2008

  • Page 1 2008 SEAT Sport UK Technical Manual – New Leon Cupra...

  • Page 2: Table Of Contents

    Wheels and Steering Tyres Weight Fuel Silencing Appendix A Engine Return Checklist Appendix B Gearbox Return Checklist Appendix C Loan Engine Contract Appendix D Loan Transmission Contract 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

  • Page 3: Introduction

    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. measurements and restraints are to be as listed and referenced from an Official SEAT Sport UK Reference Specification Car and/or parts.

  • Page 4: General

    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)
  • Page 5 See section 8 See section 8 Rear Wing 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)

  • Page 6: Tightening Torques

    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)
  • Page 7 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 8 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 9 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 10 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 11 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 12 Front Damper V4PL413031 1000 Dyno at SEAT Sport UK Rear Damper V4PL513025 1000 Dyno at SEAT Sport UK Front Damper Spherical SSV2ML407502A 6000 Check free play Joint 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 13 Intercooler 1K0145803A Every event Visual/Pressure check LH/V4PL615297 Check for cracks and free Front Brake Discs Every event RH/V4PL615298 play in bells Power Steering Hoses season Visual check 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

  • Page 14: Safety Requirements

    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.

  • Page 15: General Technical Requirements

    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: Front Toe: 15’...

  • Page 16: Chassis

    Chassis: (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.
  • Page 17 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)
  • Page 18 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)
  • Page 19 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. Diagram 9 Diagram 10 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 20 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 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

  • Page 21: Bodywork

    For further information, please contact the SCC Technical Manager. Diagram 13 Diagram 14 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 22 The air ducts outlined in red in diagram 15 may be supplied by SEAT Sport UK in aluminium or Twintex. For the avoidance of doubt, both are permitted for use within the Championship. Diagram 15 Rear Diffuser The rear diffuser is not adjustable in any way and must be attached in the correct manner intended, location and orientation as those supplied by SEAT Sport UK.
  • Page 23 All the following data has been taken with an equal front and rear ride height. Diagram 16 Glass and Transparent Surfaces (5.6.9) Glass and transparent surface specifications must remain as those supplied by SEAT Sport UK. • Front quarter windows are glass with safety laminate fitted.
  • Page 24 Adhesive foil tape may be used to seal the drain hole in the underside of the bonnet (marked ‘A’ in diagram 18). The use of a body sealer is permitted around the retaining clips of the bonnet trim (SEAT Sport UK Part No.: 1P0 854699 H).

  • Page 25: Engine

    Engine: (5.7) Engine Sealing (5.7) The location and fitment of SEAT Sport UK Confirmation Seals are shown in the following diagrams. (i) Cam belt cover to cam cover seal. (ii) Cam cover to cam end housing seal. 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 26 (iii) Cam cover to cam end housing SEAT Spain seal. (iv) Cam end plate to CCS unit seal. 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 27 (v) High-pressure fuel pump seal. (vi) Intake manifold seal. (vii) Front sump seal. 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 28 (viii) Rear sump seal. (ix) Throttle body to air temp sensor seal. (x) Throttle body seal. 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 29 Engine Parts That May Be Replaced (5.7.1) Only parts within the SEAT Sport UK Parts Manual may be used to replace accessible parts, i.e. parts with no SEAT Sport UK Confirmation Seal. Prohibited Modifications (5.7.2) Modifications to the engine in any form are prohibited including exhaust ports and manifold. Diagram 19 shows the finish of the exhaust ports.
  • Page 30 Mandatory engine oil type and manufacture is T.B.C. SEAT Sport UK recommends that Engine oil should be replaced after every Meeting. The quantity needed to fill the engine with oil filter replacement is 4.5 litres. It is recommended to change the oil filter each time the engine oil is changed.
  • Page 31 Turbo (5.7.5.1) All turbo chargers are pre-calibrated, non-adjustable, sealed units sealed by SEAT Sport UK with SEAT Sport conformation seals, as shown in diagram 21 (clamp seal) and diagram 22 (clamp to intake seal) and must remain as those supplied by SEAT Sport UK at all times.
  • Page 32 (0.010”) of travel on the actuator rod “1”. Diagram 24 The turbine housing is incorporated into the exhaust manifold and is of a roughcast finish shown in diagram 25. Diagram 25 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 33 Air Filtration Unit (5.7.5.5) SEAT Sport UK Part No. = V4PL133838. SEAT Sport UK recommends that the air filter should be checked every meeting and cleaned and re-oiled when necessary depending on its condition. When racing in very wet conditions the air filter may become waterlogged resulting in an air mass meter fault being recorded in the engine ECU, to help reduce the chances of this occurring the following modification may be carried out.
  • Page 34 Electronic Control Unit (5.7.7) All ECU’s are sealed by SEAT Sport UK with SEAT Sport conformation seals. ECU location. ECU number. ECU UK seal. ECU SEAT Spain seal. Starting The correct procedure for engine start up and engine shut down, to prolong engine serviceability is as follows: •...
  • Page 35 Fitted in the engine bay is a homologated 'Dry break connector' for draining and sampling fuel. To empty the fuel tank there is a pump out control switch available from SEAT Sport UK, Part No. U4PL 971 001. Caution! Do not run the lift pumps dry, as this will result in damage.

  • Page 36: Suspension

    Front Upright Front upright is of cast alloy construction and is designed to be ambidextrous. It is shown in diagram 28 and 29. Diagram 28 Diagram 29 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 37 Rear lateral links are of fabricated steel construction and are designed to be ambidextrous. The rear camber and toe adjustment (Regulation 5.8.8.1 and 5.8.8.2) can be adjusted on the lateral links shown in diagram 31. Diagram 31 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 38 Rear Sub-Frame All new rear sub frames supplied by SEAT Sport UK will include an increased clearance for the exhaust. For the avoidance of doubt, both the original rear sub-frame and re-designed part are permitted within the Championship. Original Design: SEAT Sport UK Part No. V4PL505315 New Design: SEAT Sport UK Part No.
  • Page 39 Front Damper. Front damper top mount, SEAT Sport UK Part No: V2ML412351. For the ease of servicing, the bore marked “A” (shown in the diagram 32) should be a clearance fit over the damper shaft. If the fit is incorrect, please contact the SCC Technical Manager.

  • Page 40: Rear Springs

    160-60-110 VN0020065900 160-60-130 Rear Springs Only the following rear spring options are permitted to be used: Reference Rear springs VN0020065100 160-60-50 VN0020065200 160-60-60 VN0020065300 160-60-70 VN0020065400 160-60-80 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 41 The rear bump stop is inclusive of the rear damper. Extra bump stop spacers may be fitted, SEAT Sport Part No. V4PL413139, to the front. These are to prevent the spring from going coil-bound. As a guide, the table below shows spring and bump stop spacer combinations.
  • Page 42 Championship. In order to fit V4PL411303A there is also a change of front anti-roll bar mount to SEAT Sport UK Part No. V4PL411355A. Diagram 36 Diagram 37 Front anti-roll bar, SEAT Sport Part No.
  • Page 43 =32 mm. Diagram 39 New rear anti-roll bars supplied by SEAT Sport UK will be SEAT Sport UK Part No. V4PL511407A as shown in diagram 41. This supersedes SEAT Sport UK Part No. V4PL511407, as shown in diagram 40. For the avoidance of doubt, both the original front anti-roll bar and redesigned part are permitted within the Championship.
  • Page 44 “Ground Clearance. The clearance between the ground and the lowest part of the bodywork, or of the suspended part of the car, in normal trim with the driver aboard [C(b) 26(j)]” 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 45 Wheel spacer dimensions are shown in diagram 43. The only wheel spacers permitted to be used are listed as follows: Front axle: = no spacer. Rear axle: = 10mm thick. Diagram 43 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

  • Page 46: Transmission

    It is recommended to make a transmission inspection every 3000km. The transmission inspections must be performed by SEAT Sport UK. Transmission returned to SEAT Sport UK for repair will only be accepted if they are free of oil and in a clean condition.
  • Page 47 Differential (5.9.6) The specified maximum differential torque is 70 NM. The differential pre-load is set by SEAT Sport UK and is non adjustable. The specified pre-load torque is to be checked at ambient temperature during assembly pre installation. Gearbox Mode Module This SEAT Sport control module centralises all the DSG gearbox controls onto the steering wheel.
  • Page 48 If the engine does not rev freely lift off the throttle pedal wait for a moment and press it again; Release the brake pedal and the vehicle will launch off. 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 49 Transmission Lubrication (5.9.9) Transmission oil should be replaced after 3 events or 1000 km. Mandatory oil is SEAT Sport Part No. G052182A2. The oil quantity is 7.2 litres. Transmission Oil Level To check the transmission oil level use the following sequence: With the engine running and transmission in neutral, at a temperature of 35°C, unscrew oil inspection plug...
  • Page 50 Diagram 47 Loan Transmission A Loan Transmission Scheme will be made available to competitors at the discretion of SEAT Sport UK. Details of the Loan Transmission contract, terms and conditions for the transmission loan are included at the end of this manual or from the SEAT Cupra Championship Parts Department.

  • Page 51: Electronics

    Engine is running. Data logger (5.10.6) The AiM data logger fitted to the Car must remain as those supplied by SEAT Sport UK including the software configuration. Please be aware that any software or hardware support will be undertaken at the Competitor’s/Team’s cost.
  • Page 52 It is the Competitors responsibility to ensure that the data system and sensors are functional and logging at all times. Any data or channels found not to be in full working order by either the SEAT Sport UK representative or the Championship Eligibility/Safety Scrutineer may be considered a breach of Technical Regulations.
  • Page 53 Battery Master Switch This type of circuit breaker has small power consumption when switched on, enough to drain the battery if connected for a long period (24 hours). 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 54 It is permitted to replace the original fuel pump fuse rated at 10A, with a 15A fuse. No other fuses may be up rated or modified, diagram 49 shows a 15 amp fuel pump fuse. Diagram 49 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

  • Page 55: Brakes

    Calliper Heat Shields The SEAT Sport UK brake calliper heat shield (SEAT Sport UK Part No. NS698472B) may be inserted in both the right and left hand front brake callipers between the calliper and brake pads (four heat shields per car).
  • Page 56 Brake Fluid Castrol SRF is the recommended brake fluid. Do not mix types of brake fluid as this can affect the seals. 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

  • Page 57: Wheels And Steering

    Steer Column Position The steering column is adjustable in height and length; the steering column must remain as supplied by SEAT Sport UK. Except for fitting optional steering column mounts to increase the height adjustment, SEAT Sport UK Part No. SCC07001KIT.

  • Page 58: Tyres

    Tyres: (5.13) Tyre Pressures (5.13.15.1) Minimum cold tyre pressure is = 1.6 bar. Minimum recommended hot tyre pressure = 2.3 bar. 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

  • Page 59: Weight

    The ballast weight must be mounted in a dimensional box of 400mm x 400mm, that is at least 200mm forward of the battery box and 30mm from the inner sill panel, shown in diagram 54. Diagram 54 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 60 Fuel: (5.15) Fuel Sample (5.15.3.4) To assist with the removal of fuel, the system is fitted with a dry break connection, shown in diagram 55. Diagram 55 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

  • Page 61: Silencing

    Exhaust down/front pipe, SEAT Sport UK Part No. = V4PL253091A. New Exhaust tail pipe/catalysts supplied by SEAT Sport UK will be SEAT Sport UK Part No. V4PL253025B. This supersedes SEAT Sport UK Part No. V4PL253025. For the avoidance of doubt, both the original exhaust tail pipe/catalysts and the redesigned part are permitted within the Championship.
  • Page 62 Diagram 57 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 63 Appendix A: Engine Return Checklist On returning an engine to SEAT Sport UK it must be dressed as follows: • Be free of oil and in a clean presentable condition. • Include an estimated mileage _________ Certain ancillaries MUST be removed and others MUST remain on the engine.
  • Page 64 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 65 Appendix B: Transmission Return Checklist On returning a Transmission to SEAT Sport UK it must be dressed as follows: • Be free of oil and in a clean presentable condition. • Complete with oil cooler and filter Ancillaries to be REMOVED FROM TRANSMISSION •...
  • Page 66 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 67 Loan Engine Contract The Loan Engine Scheme available to competitors is at the discretion of SEAT Sport UK. The Loan Engine is to be used only for the replacement of a complete engine (with all SEAT Sport UK Confirmation Seals intact and in good condition) that has incurred damage and is no longer usable through either a mechanical failure or misuse.
  • Page 68 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)
  • Page 69 If the damaged transmission is beyond economical repair, the Competitor will be liable for a full transmission replacement cost, or will have the option to purchase the Loan Transmission at full SEAT Sport UK price, or return the Loan/Replacement Transmission back to SEAT Sport UK with costs incurred as listed above, plus any transportation costs by the date agreed.
  • Page 70 Prepared by Northern South for SEAT Sport UK 2008 SEAT Sport UK, Technical Manual – New Leon Cupra v3 (Autosport International)

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