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Seat New Leon Cupra 2008, Technical Manual, Page: 1 / 70

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2008 SEAT Sport UK 

Technical Manual – New Leon Cupra 

 

 
 

 
 

 

 
 
 

 

Summary of Contents for New Leon Cupra 2008

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

Page 2: ...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 5...

Page 3: ...d 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 20...

Page 4: ...nd 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 B...

Page 5: ...810mm 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 withi...

Page 6: ...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...

Page 7: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 6...

Page 8: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 7...

Page 9: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 8...

Page 10: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 9...

Page 11: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 10...

Page 12: ...k 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...

Page 13: ...PL615106 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...

Page 14: ...ement 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...

Page 15: ...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 Fron...

Page 16: ...d 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 be...

Page 17: ...range 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 th...

Page 18: ...t International 17 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 P...

Page 19: ...tions 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 pl...

Page 20: ...on Cupra v3 Autosport International 19 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 07006...

Page 21: ...ded location and orientation as those supplied by SEAT Sport UK To help prevent the rubber build up from collecting under the front edge of the centre section of the flat floor and to increase the cle...

Page 22: ...mitted 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 sup...

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 supplie...

Page 24: ...ar the spark plug in cylinder number 4 can suffer from water ingress To help prevent the build up of water around the spark plug coil pack the following modifications may be carried out Adhesive foil...

Page 25: ...eon Cupra v3 Autosport International 24 7 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 s...

Page 26: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 25 iii Cam cover to cam end housing SEAT Spain seal iv Cam end plate to CCS unit seal...

Page 27: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 26 v High pressure fuel pump seal vi Intake manifold seal vii Front sump seal...

Page 28: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 27 viii Rear sump seal ix Throttle body to air temp sensor seal x Throttle body seal...

Page 29: ...ent Engine Rebuild If a Team Competitor requires an Engine rebuild SEAT Sport UK shall supply its engine partner with a complete set of parts as standard procedure The kit comprises all the parts requ...

Page 30: ...rt of an Official Test qualifying session or race the engine oil level must be at the maximum level The oil level shall remain between the two marks in the oil dipstick as shown in diagram 20 The dips...

Page 31: ...am 21 clamp seal and diagram 22 clamp to intake seal and must remain as those supplied by SEAT Sport UK at all times Diagram 21 Diagram 22 Please be aware that turbos must be made available to the Cha...

Page 32: ...made with a Dial Test Indicator DTI positioned onto the waste gate actuator rod as shown in diagram 24 The crack off point at which the waste gate valve 2 lifts off its seat is to 10 thousandths of a...

Page 33: ...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...

Page 34: ...tart up and engine shut down to prolong engine serviceability is as follows Always switch the master switch on before the ignition switch Start up procedure The Engine MUST be idled for at least 2 min...

Page 35: ...ted 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 Ca...

Page 36: ...nical Manual New Leon Cupra v3 Autosport International 35 8 Suspension 5 8 Front Upright Front upright is of cast alloy construction and is designed to be ambidextrous It is shown in diagram 28 and 29...

Page 37: ...e ambidextrous The front camber adjustment Regulation 5 8 7 1 is adjusted on the bottom ball joint mounting point shown in diagram 30 Diagram 30 Rear Lateral Links Rear lateral links are of fabricated...

Page 38: ...ear 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 C...

Page 39: ...K 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 Manage...

Page 40: ...ster Diagram 35 Springs 5 8 6 2 All front and rear spring options are to be mounted with a 60 60 2 helper spring part No VN0020018100 except the 250 60 70 which is used without helper spring The car i...

Page 41: ...ting length Car height Bump stop package 250 60 70 238 mm 60mm to 80mm Bump stop 1x bump spacer 174 mm 60 mm Bump stop 1x bump spacer 174 to 169 mm 65 mm Bump stop 2x bump spacers 169 to 164 mm 70 mm...

Page 42: ...ne to adjustment 2 226 mm Tube centerline to adjustment 3 198 mm New front anti roll bars supplied by SEAT Sport UK will be SEAT Sport UK Part No V4PL411303A as shown in diagram 37 This supersedes SEA...

Page 43: ...2 mm Shown in diagram 39 adjustment 1 to adjustment 2 16 mm adjustment 1 to adjustment 3 32 mm Diagram 39 New rear anti roll bars supplied by SEAT Sport UK will be SEAT Sport UK Part No V4PL511407A as...

Page 44: ...to centre 250mm Front left hand adjustable N A Rear right hand fixed length centre to centre 100mm Rear left hand adjustable N A Ride Height 5 8 5 Minimum ride height 55mm The ride height is to be me...

Page 45: ...eon Cupra v3 Autosport International 44 Wheel spacers 5 8 9 3 and 5 8 9 4 Wheel spacer dimensions are shown in diagram 43 The only wheel spacers permitted to be used are listed as follows Front axle n...

Page 46: ...ear ratios Specific mechanical limited slip differential The replacement of the gear lever with a gearbox mode module and two pads on the steering wheel Specific software Sealed with SEAT Sport confor...

Page 47: ...engine is started up If you need to keep the vehicle stationary with the engine running select neutral otherwise the car will stay in first gear and move forward slowly if the brake is not applied Tip...

Page 48: ...utton once in accordance with the current mode Reverse Mode This mode selects reverse gear Display The mode indicator shows a red R The screen shows the letter R To access reverse From neutral mode N...

Page 49: ...n the level tube shown in diagram 46 The gear oil level is correct when a small amount of oil still drains out when the oil temperature is between 35 C and 45 C Note Every 30 seconds a small surge of...

Page 50: ...in a clean condition The transmissions must to be dressed as per the checklist in Appendix B SEAT Sport UK cannot guarantee the return of any additional ancillaries left on the transmission Parts mis...

Page 51: ...ircuit must be connected as supplied and operational as intended by SEAT Sport UK at all times whilst the Engine is running Data logger 5 10 6 The AiM data logger fitted to the Car must remain as thos...

Page 52: ...wheel speed RL Speed RL wheel speed RR Speed RR wheel speed Fuel level Fuel tank gauge P oil Engine oil pressure P brake F Front brake pressure P brake R Rear brake pressure Acc 1 Lateral G force Gear...

Page 53: ...nd fire extinguisher are shown in diagram 48 Diagram 48 Steering Column Controls The controls on the steering column are the same as the road car i e the indicators windscreen wipers and headlights Th...

Page 54: ...n Cupra v3 Autosport International 53 Fuse and Relay Box Lay Out 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...

Page 55: ...erted in both the right and left hand front brake callipers between the calliper and brake pads four heat shields per car Brake Pads Front brake pads are a control pad supplied by SEAT Sport UK Part N...

Page 56: ...rs When satisfied with the pushrod adjustment tighten both of the lock nuts on pushrods The smaller bore master cylinder has the long push rod see diagram 50 Brake Balance The brake balance can be adj...

Page 57: ...h 30mm 1mm Lock restrictor shown in diagram 52 Diagram 52 Steering Arm The steering arm is of fabricated steel construction and is designed to be ambidextrous The adjustor should remain secure in the...

Page 58: ...08 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 57 13 Tyres 5 13 Tyre Pressures 5 13 15 1 Minimum cold tyre pressure is 1 6 bar Minimum recommended hot tyre pressure 2 3 ba...

Page 59: ...unted in a dimensional box that is at least 140mm from the inner sill panel and 60 mm from the heel panel shown in diagram 53 Diagram 53 Car Ballast 5 14 6 2 To achieve 5 14 2 ii ballast must be mount...

Page 60: ...UK Technical Manual New Leon Cupra v3 Autosport International 59 15 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...

Page 61: ...aust tail pipe catalysts and the redesigned part are permitted within the Championship Exhaust Specification Exhaust down front pipe comprises of an 80mm 1mm bore pipe with a flexible section and sect...

Page 62: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 61 Diagram 57...

Page 63: ...moved and others MUST remain on the engine Ancillaries to be LEFT ON THE ENGINE Engine mount bracket Engine wiring harness Plastic water outlet on front of engine Alloy bracket for carrying PAS and al...

Page 64: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 63...

Page 65: ...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 Ancill...

Page 66: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 65...

Page 67: ...only be transported on a frame or in a flight case supplied by SEAT Sport UK Seals must not be tampered with in any way as per the 2008 SEAT Cupra Championship Regulations The water system must be bl...

Page 68: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 67...

Page 69: ...Sealed Transmission to be supplied The transmission must and may only be transported in a flight case supplied by SEAT Sport UK Seals must not be tampered with in any way as per the 2008 SEAT Cupra C...

Page 70: ...2008 SEAT Sport UK Technical Manual New Leon Cupra v3 Autosport International 69 Prepared by Northern South for SEAT Sport UK...

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