Seat 2015 LEON CUP RACER Workshop Manual
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Seat 2015 LEON CUP RACER Workshop Manual

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LEON CUP RACER
2015
WORKSHOP MANUAL

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Summary of Contents for Seat 2015 LEON CUP RACER

  • Page 1 LEON CUP RACER 2015 WORKSHOP MANUAL...
  • Page 2 WORKSHOP MANUAL LEON CUP RACER 1 de 69...

  • Page 3: Table Of Contents

    WORKSHOP MANUAL LEON CUP RACER INDEX TURBOCHARGER ........................3 Turbocharger, exploded view ..................3 Turbo compressor: removing and fitting ..............9 IGNITION SYSTEM ........................ 18 Ignition system: Assembly overview ................18 Ignition coils with output stage: removing and fitting ..........20 OIL SUMP ..........................

  • Page 4: Turbocharger

    WORKSHOP MANUAL LEON CUP RACER TURBOCHARGER Turbocharger, exploded view Part I Part II → Anchor 1 - O-ring Renew  Lubricate lightly with engine oil  3 de 69...
  • Page 5 WORKSHOP MANUAL LEON CUP RACER 2 - Bolt 9 Nm.  3 - Coolant supply line 4 - O-ring Renew  Lubricate with coolant  5 - Seal Renew  6 - Nut Renew  25 Nm.  7 - Turbocharger remove and install →...
  • Page 6 WORKSHOP MANUAL LEON CUP RACER 9 Nm.  15 - Bolt 9 Nm.  16 - Coupling 17 - O-ring replace  18 - Bolt 9 Nm.  5 de 69...
  • Page 7 WORKSHOP MANUAL LEON CUP RACER Part II Part I → Anchor 1 - Bolt 9 Nm.  2 - Oil return line 3 - O-ring Renew  6 de 69...
  • Page 8 WORKSHOP MANUAL LEON CUP RACER Lubricate lightly with engine oil  4 - Bolt 9 Nm.  5 - Charge pressure positioner -V465- 6 - Nut If nut has been loosened, charge pressure positioner -V465- must be renewed  10 Nm. ...
  • Page 9 WORKSHOP MANUAL LEON CUP RACER 16 - Bolt 9 Nm.  17 - Bolt 9 Nm.  18 - Coolant return line 19 - O-ring Renew  Lubricate with coolant  20 - O-ring Renew  Lubricate lightly with engine oil ...

  • Page 10: Turbo Compressor: Removing And Fitting

    WORKSHOP MANUAL LEON CUP RACER Fitting location of turbocharger air recirculation valve -N249- – Note installation position - arrows-. Turbo compressor: removing and fitting Caution If a mechanical fault is discovered on the turbocharger (e.g. a destroyed compressor impeller), it is not sufficient to just renew the turbocharger.
  • Page 11 WORKSHOP MANUAL LEON CUP RACER Engine bung set -VAS 6122-  Hose clip pliers -VAS 6362-  Support tool -T10038-  Removing Caution Risk of malfunctions caused by dirt. → Chapter „Cleaning Observe rules“. – Drain coolant → Chapter. Removing front exhaust pipe –...
  • Page 12 WORKSHOP MANUAL LEON CUP RACER Release the hose clamp - – Remove bolt -1- and press – air pipe (left-side) towards left slightly. Remove coolant hose - – arrow-. Separate connectors -1- and – -2-. Open retainer -3-. 11 de 69...
  • Page 13 WORKSHOP MANUAL LEON CUP RACER Remove bolt -1- for earth – cable and remove coolant hose -2-. – Pull off connector -arrows-. Release fastener -arrow- – and remove wiring duct -4- upwards from bracket. Unscrew the bolts -1, 2 – and 3-.
  • Page 14 WORKSHOP MANUAL LEON CUP RACER Remove actuators for – camshaft adjustment - arrows-. Removing ignition coils – with output stages → Chapter Remove bolts -arrows- – and nut -1-. – Detach heat shield -2-. 13 de 69...
  • Page 15 WORKSHOP MANUAL LEON CUP RACER Remove bolt -1- and – loosen bolt -3-. Remove bracket -2- for – turbocharger. Detach electrical – connectors -1, 3-. Press release tabs on – crankcase breather hose - 2- and detach hose. 14 de 69...
  • Page 16 WORKSHOP MANUAL LEON CUP RACER Remove bolts -1- and – detach connection. Unscrew bolts -2, 3- and – detach oil supply line and oil return line. – Release hose clip -arrow-. Note The following procedure is necessary to provide more space between the cylinder head and bulkhead.
  • Page 17 WORKSHOP MANUAL LEON CUP RACER Pull engine back approx. 20 – mm with tensioning strap - T10038-. – Remove nuts -arrows-. Detach turbocharger from – cylinder head. Installation Installation is carried out in the reverse order; note the following: Note Replace the seals, the gaskets, O-rings and the ...
  • Page 18 WORKSHOP MANUAL LEON CUP RACER → Chapter. Fill up with coolant – → Anchor. Check oil level – → Booklet501. Note After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil.

  • Page 19: Ignition System

    WORKSHOP MANUAL LEON CUP RACER IGNITION SYSTEM Ignition system: Assembly overview 1 - Bolt replace  20 Nm.  Tightening torque influences functions of knock sensor  2 - Knock sensor I -G61- → Chapter „Knock sensor 1 -G61-: Removing and installing“ remove and install ...
  • Page 20 WORKSHOP MANUAL LEON CUP RACER 30 Nm.  Remove and install with key -3122 B-  Intervals for changing filter → Booklet 501 4 - Ignition coil with output stage Ignition coil 1 with output stage -N70-  Ignition coil 2 with output stage -N127- ...

  • Page 21: Ignition Coils With Output Stage: Removing And Fitting

    WORKSHOP MANUAL LEON CUP RACER 9 Nm  Ignition coils with output stage: removing and fitting Special tools and workshop equipment required Extractor -T10530-  Removing – Remove engine cover → Chapter. – If fitted, detach the earth cable. Release connectors and unplug all connectors from –...
  • Page 22 WORKSHOP MANUAL LEON CUP RACER Insert puller -T10530- into – hole -1- in ignition coil. Turn knurled nut -2- – clockwise until puller is secured in place. Working vertically upwards, – carefully pull ignition coil out with puller -T10530-. Installation Press ignition coils onto –...

  • Page 23: Oil Sump

    WORKSHOP MANUAL LEON CUP RACER OIL SUMP Assembly overview - sump, oil pump Note If large quantities of metal shavings or other particles are found in the engine oil when repairing the engine (possibly caused by partial seizure of crankshaft and conrod bearings), clean the oil passages thoroughly and renew the engine oil cooler to prevent further damage occurring later.
  • Page 24 WORKSHOP MANUAL LEON CUP RACER 1 - Nut 9 Nm.  2 - Oil level and oil temperature sender -G266- remove and install → Chapter  3 - Seal Renew  4 - Bolt Renew  Tightening sequence → Fig. ...
  • Page 25 WORKSHOP MANUAL LEON CUP RACER 12 - O-ring Renew  Lubricate lightly with engine oil  13 - Bolt Tightening torque → Item  14 - Valve for oil pressure control -N428- remove and install → Chapter  15 - Chain tensioner 16 - Chain for operating oil pump Mark direction of rotation before removing ...
  • Page 26 WORKSHOP MANUAL LEON CUP RACER 24 - Bolt Renew  8 Nm +90°  25 - Baffle Renew  26 - Bolt Renew  4 Nm +45°  27 - Lower element on the case Different versions available → Electronic parts catalogue ...
  • Page 27 WORKSHOP MANUAL LEON CUP RACER Tightening sequence for sump (bottom section), plastic version Note Renew the bolts tightened with specified tightening angle. Tighten bolts -1 to 20- in 2 – stages as shown in the sequence: 1. Tighten bolts to 8 Nm. 2.
  • Page 28 WORKSHOP MANUAL LEON CUP RACER Upper element of the oil tray, tightening sequence Note Renew the bolts tightened with specified tightening angle. – Tighten bolts -1 to 14- in the sequence shown. stage: Tightening sequence and tightening torque 1. Bolts -1- to -14- Tighten to 8 Nm 2.

  • Page 29: Removing And Installing Oil Level/Oil Temperature Sender -G266

    WORKSHOP MANUAL LEON CUP RACER Removing and installing oil level/oil temperature sender - G266- Removing Engine oil drained  → Booklet501. – Pull out the plug -3-. Unscrew nuts -1- and remove oil level and oil – temperature sender - G266--Pos.

  • Page 30: Remove And Install The Lower Element Of The Oil Tray

    WORKSHOP MANUAL LEON CUP RACER Installing Installation is carried out in the reverse order; note the following: Note Renew seal -2-. Fill up with engine oil and check the oil level – → Booklet501. Tightening torques → Chapter „Assembly overview - sump, oil ...
  • Page 31 WORKSHOP MANUAL LEON CUP RACER Removing Remove the sound proofing -1- – → Rep. gr.66. Place the used oil collection and extraction – unit -VAS 6622A- underneath the engine and allow the oil to drain. Note Please observe requirements for disposal. Remove oil level and oil –...
  • Page 32 WORKSHOP MANUAL LEON CUP RACER Vehicles with sheet-metal version of sump (bottom section): – Remove bolts -1 … 20-. Carefully release sump – (bottom section) from bonded joint. Installation Sump (bottom section), sheet- metal version: Note Observe use-by date of ...
  • Page 33 WORKSHOP MANUAL LEON CUP RACER Cut off tube nozzle at front – marking (Ø of nozzle approx. 3 mm). Apply a line of silicon sealant, as shown in the figure, to the clean surface of the oil sump – seal. Thickness of the sealing paste bead: 2 ...

  • Page 34: Remove And Install The Upper Element Of The Oil Tray

    WORKSHOP MANUAL LEON CUP RACER Remove and install the upper element of the oil tray Special tools and workshop equipment required Pinning tool -T10118-  33 de 69...
  • Page 35 WORKSHOP MANUAL LEON CUP RACER Pinning tool -T40265-  Electric drill with plastic  brush Protective glasses  Silicone sealant:  → Electronic parts catalogue Removing Gearbox is removed.  Remove sump (bottom – → section) Chapter. Remove rear sealing flange –...
  • Page 36 WORKSHOP MANUAL LEON CUP RACER Continuation for all vehicles: – Unplug connector -1-. – Remove bolts -arrows-. 35 de 69...
  • Page 37 WORKSHOP MANUAL LEON CUP RACER Unscrew bolts -1 to 14- – and remove the upper part of the sump. Caution First lift the top part of the oil pan onto the side of the gearbox. Take care timing chain cover is not bent when levering off.
  • Page 38 WORKSHOP MANUAL LEON CUP RACER Cut off tube nozzle at front – marking (Ø of nozzle approx. 2 mm). Caution Danger of blocking lubrication system with excess sealant. Do not apply sealant bead thicker than specified. Thickness of the sealant ...
  • Page 39 WORKSHOP MANUAL LEON CUP RACER Apply silicone sealant between cylinder block – and timing chain cover (bottom), as illustrated - arrows-. Note There is a 5-minute time limit for fitting the upper part of the sump once the  silicone sealant has been applied.

  • Page 40: Intake Manifold With Throttle

    WORKSHOP MANUAL LEON CUP RACER INTAKE MANIFOLD WITH THROTTLE Intake manifold: Assembly overview 1 - Intake manifold → Chapter remove and install  2 - Bolt for intake manifold 9 Nm.  3 - Intake manifold flap valve -N316- 4 - Vacuum unit for air flow control flaps (intake manifold flaps) 5 - Bolts for the high-pressure pump .
  • Page 41 WORKSHOP MANUAL LEON CUP RACER 7 - Fuel pressure regulator valve -N276- 8 - High-pressure pump With fuel pressure regulating valve -N276-  An electric fuel pump (fitted in fuel tank) supplies fuel to the mechanical high-pressure  pump When fitting the high pressure pump, take care that no dirt enters the fuel system. ...

  • Page 42: Exploded View - Fuel Rail, Direct Injection

    WORKSHOP MANUAL LEON CUP RACER 22 - Intake manifold support nut 10 Nm.  23 - Rubber mounting 5 Nm  Exploded view - fuel rail, direct injection 1 - Injector With combustion chamber ring seal (Teflon ring seal): always renew ...
  • Page 43 WORKSHOP MANUAL LEON CUP RACER Renew  3 - Fuel rail for combustion chamber injectors tighten to 9 Nm  → Chapter removing and fitting  4 - Roller tappet 5 - Fuel pressure regulator valve -N276- 6 - High-pressure pump With fuel pressure regulating valve -N276- ...
  • Page 44 WORKSHOP MANUAL LEON CUP RACER 13 - Port separator plates 14 - Seal Check for damage and renew if necessary  15 - Adjuster for air flow control flaps (intake manifold flaps) 16 - Vacuum unit for air flow control flaps (intake manifold flaps) 17 - Intake manifold flap valve -N316- 18 - Intake manifold sender -GX9- comprising:...

  • Page 45: Exploded View - Fuel Rail, Intake Manifold Injection

    WORKSHOP MANUAL LEON CUP RACER Exploded view - fuel rail, intake manifold injection 1 - Bolt for fuel rail for intake manifold injectors  9 Nm.  2 - Fuel rail for intake manifold injectors 3 - O-ring Renew  4 - Injector Replace the O-rings.
  • Page 46 WORKSHOP MANUAL LEON CUP RACER 8 - High-pressure pump With fuel pressure regulating valve -N276-  An electric fuel pump (fitted in fuel tank) supplies fuel to the mechanical high-pressure  pump When fitting the high pressure pump, take care that no dirt enters the fuel system. ...

  • Page 47: Intake Manifold: Removing And Installing

    WORKSHOP MANUAL LEON CUP RACER Renew O-ring.  15 Nm.  27 - O-ring Renew  28 - Clamp For securing fuel pressure sender for low pressure -G410- in fuel rail  Intake manifold: Removing and installing Special tools and workshop equipment required Pinning tool -T10118- ...
  • Page 48 WORKSHOP MANUAL LEON CUP RACER Socket -T10347-  After the intake manifold has been removed or renewed, the intake manifold flap potentiometer -G336- must be adapted to the engine control unit -J623-. Removing Caution Risk of severe damage to the electronic components when disconnecting the battery.
  • Page 49 WORKSHOP MANUAL LEON CUP RACER Screw out left and right- – hand bolts -arrow-. Unclip air duct (bottom – section) -1- and detach. Remove the sound proofing -1- – → Rep. gr.66. – Free coolant hose -3-. Unplug electrical – connector -1- at charge pressure sender -G31-.
  • Page 50 WORKSHOP MANUAL LEON CUP RACER Unplug the following – electrical connectors: from the combustion chamber injectors From knock sensor 1 - G61- Stage 3 oil pressure switch -F447- For intake manifold flap valve -N316-, fuel pressure sender - G247-, intake manifold flap potentiometer - G336-, coolant temperature sender -...
  • Page 51 WORKSHOP MANUAL LEON CUP RACER Unplug electrical connector for intake – manifold flap valve -N316- -2-. Disconnect vacuum lines - arrows- from intake – manifold flap valve -N316- -2- and from air cleaner housing. Unscrew bolt -1- and push – air pipe clear to left side.
  • Page 52 WORKSHOP MANUAL LEON CUP RACER Unscrew retaining clip - – arrow- for high-pressure pipe. Open union nuts securing high-pressure pipe to high- – pressure pump and fuel rail. Take out high-pressure – pipe. Note The fuel system must not  be under pressure.
  • Page 53 WORKSHOP MANUAL LEON CUP RACER Unplug electrical connector -1- from intake – manifold flap potentiometer -G336-. Unscrew bolts from intake – manifold using socket Torx T30 -T10347-. Pull the intake manifold away a little from the – cylinder head and unscrew the holder for the electrical connectors.

  • Page 54: Removing And Installing Throttle Valve Module -Gx3

    WORKSHOP MANUAL LEON CUP RACER Removing and installing throttle valve module -GX3- Throttle valve control unit -GX3- comprises: Throttle valve drive (electric power control) -G186-  Throttle valve drive angle sender 1 (electric power  control) -G187- Throttle valve drive angle sender 2 (electric power ...
  • Page 55 WORKSHOP MANUAL LEON CUP RACER Remove bolt -arrow- on – both sides. Unclip air duct (bottom – section) -1- and detach. Remove the sound proofing -1- – → Rep. gr.66. Release hose clip -2- and – detach air hose from charge air cooler.
  • Page 56 WORKSHOP MANUAL LEON CUP RACER – Free coolant hose -3-. Unplug electrical – connector -1- at charge pressure sender -G31-. – Remove bolts -arrows-. Release hose clip -2- on air hose and pull air hose – off throttle valve module - J338-.

  • Page 57: Alternator

    WORKSHOP MANUAL LEON CUP RACER ALTERNATOR Alternator without sliding bushes -exploded view- 1 - Plug  23 Nm  2 - Alternator: → Chapter Removing and installing  → Chapter repairs  3 - Connector 4 - Terminal 30/B+ 5 - Cap 6 - Nut ...

  • Page 58: Removing And Installing The Alternator, Vehicles With 1.8 Litre Tsi Engine

    WORKSHOP MANUAL LEON CUP RACER Removing and installing the alternator, vehicles with 1.8 litre TSI engine Special tools and workshop equipment required Torque wrenches -V.A.G  1331- Engine bung set -VAS 6122-  Removal: With ignition switched off, – disconnect earth cable from →...
  • Page 59 WORKSHOP MANUAL LEON CUP RACER Unscrew the attachment – bolts -1- and -2- of the generator (alternator). Remove the lower engine noise insulation – → Rep. gr.50. – Loosen hose clip -1-. Note Ignore -item 2-. 58 de 69...
  • Page 60 WORKSHOP MANUAL LEON CUP RACER Move clear coolant hose - – – Release hose clip -2-. – Remove bolts -arrows-. – Unplug connector -1-. – Remove the air pipe. Seal open lines and connections with suitable – plugs from engine bung set -VAS 6122-.
  • Page 61 WORKSHOP MANUAL LEON CUP RACER Uncover the electrical – wiring line -Arrow-. Unscrew bolts -5- and -6- – and move alternator -C--4- towards front. – Unplug connector -3-. Remove the cover -2-, by – levering. Unscrew nut and remove – terminal 30/B+ -1-.

  • Page 62: Tightening Torques: Alternator

    WORKSHOP MANUAL LEON CUP RACER Tightening torques: Alternator: Threaded connections Specified torques Cable B+ to alternator 16 Nm Air conduction tube to Engine block 15 Nm Rear bracket 8 Nm Fasten cables to alternator 3.2 Nm Voltage regulator to alternator 2 Nm Protector to alternator 4.5 Nm...

  • Page 63: Differential

    WORKSHOP MANUAL LEON CUP RACER DIFFERENTIAL Assembly overview – Front differential lock 1 - Front differential lock → Chapter Removal  → Chapter Installing  2 - Countersunk bolt 30 Nm  3 - Heat shield For drive shaft  4 - Nut Qty.

  • Page 64: Removing Front Differential Lock

    WORKSHOP MANUAL LEON CUP RACER → Rep. gr.40 5 - Plug  Replace after each removal  40 Nm + 90°  Removing front differential lock Special tools and workshop equipment required Socket and key -T10107 A-  Torque wrench -V.A.G 1331- ...
  • Page 65 WORKSHOP MANUAL LEON CUP RACER Remove drive shaft heat shield, if present, from – bevel box (-arrows-) → Rep. gr.40. Remove right-hand drive shaft – → Rep. gr.40. Caution Risk of damage to decoupling element. → Rep. gr.26. Remove front exhaust pipe from engine and tie it –...
  • Page 66 WORKSHOP MANUAL LEON CUP RACER Detach connector -1- from oil – level and oil temperature sender -G266-. Unscrew pendulum support – bolts -1- from gearbox. Remove securing bolt for right flange shaft with socket – by screwing 2 bolts into flange and counterholding flange shaft with a lever.
  • Page 67 WORKSHOP MANUAL LEON CUP RACER Unscrew upper securing bolts -arrows- for securing – front differential lock to gearbox. Unscrew lower securing bolts -arrows- for securing – front differential lock to gearbox. Have a second mechanic push engine/gearbox – assembly towards front end slightly.

  • Page 68: Installing Front Differential Lock

    WORKSHOP MANUAL LEON CUP RACER Installing front differential lock Installation is carried out in the reverse sequence; note the following: Have a second mechanic push engine/gearbox – assembly towards front end. Push front differential lock completely onto gearbox. When doing this, join flange shaft/front differential lock –...
  • Page 69 WORKSHOP MANUAL LEON CUP RACER Screw in upper securing bolts -arrows- for front – differential lock and tighten them. Tightening torque: → Item Bolt on flange shaft. – → Item Tightening torque: Install new bolts-1- to secure the pendulum support –...
  • Page 70 WORKSHOP MANUAL LEON CUP RACER Connect connector -arrow- to – transverse lock-up control unit -J647-. Install right-hand drive shaft – → Rep. gr.40. If fitted, install drive shaft heat shield -arrows- – → Rep. gr.40. Top up gear oil in front –...
  • Page 71 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 72 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 73 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 74 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 75 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 76 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 77 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 78 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 79 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 80 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 81 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...
  • Page 82 Safety-doc. Appr. incl. Están reservados todos los derechos de disposición, en especial a copiar o distribuir. ProE Konst.Verantw./Design resp. All rights remain with SEAT SPORT. This applies especially to rights of invention, 23/04/14 OSN Edición Name Konstrukteur A. Almirall ©...

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