SEAT LCR TCR V3 DSG Tightening Torque Manual

Transcription

1 SEAT LCR TCR V3 DSG Tightening Torque Manual

2 INDEX Notes 3 Engine Fly Wheel And Clutch 4 Engine & Gearbox Supports 5 Turbocharger 6 Alternator 7 Fuel System 8 Intermediate Axle 10 Drive Shaft 11 Front Upright And Hub 12 Front Brake 13 Front Subframe 14 Front Wishbone 15 Front Shock Absorber 16 Steering Rack & Column 17 Rear Upright 18 Rear Shock Absorber 19 Rear Subframe 20 Pedal Box 21 Front & Rear End 22 Backet Seat 23 Ballast Fixation 24 DSG Gearbox 25 2

3 NOTES In this manual you will find the tightening torques of the vehicle with exploded views. Attached to the different parts there is a reference with some information. There is an example here below to understand how to read it: TO BODY SHELL VN BOLT M10x30 60 Nm It Explains Where The Part Is Assembled On. Catalogue Reference Name Size & Torque Additional Useful Information Besides the reference, the bolts, nuts, spacers and bushes may be marked with a color spot next to them. The ones with the same color spot have the same information and thus the same tightening torque. If no color spot is found means that the part is a single unit. The colors are common in one single page and are not related between different pages. Spot colors: 3

4 ENGINE FLY WHEEL AND CLUTCH OIL FILTER CAP 50 Nm Moisten the o-ring with some oil before assembly. 4

5 ENGINE & GEARBOX SUPPORTS VN M12x150x35 80 Nm VN M10x30 80 Nm VN M10x65 60 Nm _N M6x16 15 Nm _N NUT M10 _N M10x65 60 Nm _N M10x50 60 Nm _N M10x35 60 Nm 5

6 TURBOCHARGER TO REPLACE THE TURBOCHARGER USE ALWAYS: NEW EXHAUST GASKET NEW NUTS NEW EXHAUST CLAMP 6

7 ALTERNATOR 7

8 FUEL SYSTEM VN NUT M4 By Hand VN NUT M4 By Hand 8JR CLAMPING RING 8JR FUEL PUMP REPLACE AFTER 8000 KM. OR ONCE PER SEASON 8JR DECOUPLING PART PRESS FIT 8JR FUEL PUMP WIRING SET 6 Nm THERE IS ONLY ONE POSITION VN NUT M4 By Hand 8

9 FUEL SYSTEM VN M5x20 5 Nm VN FUEL SAFETY COUPLING - FEMALE - FIA HOMOLOGATED V8PS FIA TANK VENTILATION VALVE 35 Nm _N M6x20 10 Nm VN M5x16 5 Nm ROLL OVER VALVE VENT VALVE PRESSURE VALVE VN NUT M5 3 Nm _N NUT M6 10 Nm _N NUT M5 9

10 INTERMEDIATE AXLE 10

11 DRIVE SHAFT _1K D DRIVESHAFT SPACER VN PRESSED WASHER Ø 10,5 _N M10x52 80 Nm USE COPPER GREASE 5F A DRIVESHAFT (LH & RH) WARNING DRIVE SHAFT CAMBER USE RANGE: _WHT DOUBLE HEX. HEAD BOLT M16X1.5X Nm + 90º REPLACE WHEN TIGHTENED TWICE MIN. CAMBER: 3,8º MAX. CAMBER: 5,8º 11

12 FRONT UPRIGHT AND HUB 5F M12x84 80 Nm _N VN M10x25 60 Nm VN SELF-LOCKING NUT 80 Nm VN VN F M12x Nm _WHT Nm VN M8x35 25 Nm REMARK: FIRST TIGHTEN THE CENTRAL BOLT. TIGHTEN THE 3 BOLTS TWICE. REMARK: WHEELNUT TORQUE IS 100 Nm VN M12x75 80 Nm VN BOLT VN WASHER VN M6x25 12

13 FRONT BRAKE 5F (x12) BOLT 4UNF-6 L=27mm 05F MICA HEAT PROTECTION 8S LH 8S RH FRONT BRAKE DISC 378x34 8S DISC BELL 5F (x12) WASHER 1/4" -12,5x6,5x0,9-5F A - LH 5F A - RH BRAKE CALIPER 5F A (x12) NUT 1/4" UNF. 15 Nm 5F GASKET KIT ONLY FOR RADICAL BRAKE CALIPERS. 13

14 FRONT SUBFRAME PUT A DROP OF GREASE ON THE FRICTION ZONE CHECK THAT THE ANTI ROLL BAR IS FREE AFTER TIGHTENING 5F M8x62 40 Nm V3FL V3FL411303A ANTIROLL BAR Ø 22x3 ANTIROLL BAR Ø 22x2 (OPTION) Unibal always screwed at maximum to avoid interferences with the driveshaft. Female unibal always on the wishbone side. VN M10x150x45 40 Nm _N SELF-LOCKING M12x1,5 _N M8x70 40 Nm _N M12x1,5x Nm _N M12x1,5x Nm 14

15 FRONT WISHBONE VN FEMALE BALL JOINT Ø16X1,50 Tighten to 130 Nm + needed rotation to set the ball joint in its working position. VN VN ADJUST WASHER 12.9 Ø16 Thickness = 0,2 mm. ADJUST WASHER 12.9 Ø16 Thickness = 0,3 mm. V3FL ARM CAMBER PLATE LEFT ASSY. 5F SPHERICAL BEARING SPACER VN AVIATION NUT M10 70 Nm _WHT000785A FLAT HEXAG. NUT M12X Nm VN ALLEN BOLT M6x15 VN ALLEN BOLT ADJUSTER M10x80 VN AVIATION NUT M12 80 Nm 15

16 FRONT SHOCK ABSORBER VN AVIATION NUT M10 40 Nm VN BOLT 12,9 M10x50 60 Nm 5F BILSTEIN BUSHING VN HELPER V2MT411113C SPRING SPACER Ø 80mm. 5F B FRONT BILSTEIN SHOCK ABSORBER SPRING OPTIONS SPRING SPRING VN VN SPRING S SPRING S A SPRING S B SPRING S C 16

17 STEERING RACK & COLUMN _N M18X1.5X18 50 Nm BOLT _N By Hand HEAT SHIELD _5Q D STEERING RACK STOPPER 5F A _N M8x35 25 Nm _N M8X25 25 Nm V3FL422807A STEERING ROD _N M12x1,5x Nm 5F SPEC. - STEERING ROD UNIBAL ASSY. 17

18 REAR UPRIGHT VN M10x70 60 Nm VN WASHER Ø10 VN WASHER Ø10 VN M12x1,5x60 80 Nm 5F SPACER VN M12x65 80 Nm Wide side of spacer rests against upright surface. 1T501611E WHEEL HUB _N BOLT 15 Nm _WHT000229A M16X1,5X Nm + 90º V4PL WHEEL STUDS 130 Nm LOCTITE 270 Green PUNCHED BEHIND Place before installing wheel hub with the window for the speed sensor properly. V3FL505279A STUD 60 Nm LOCTITE 270 Green VN K-NUT M12 40 Nm VN V3FL505270B STUD & NUT 100 Nm LOCTITE 270 Green 18

19 REAR SHOCK ABSORBER VN M10X150X45 VN M10X Nm VN PRESSED TYPE WASHER _N HEXAGON HEAD M10X35 60 Nm V3FL SPACER VN HELPER V2MT411113C SPRING SPACER Ø 80mm. SPRING OPTIONS SPRING SPRING VN VN VN M10X Nm SPRING S SPRING S A SPRING S B SPRING S C 19

20 REAR SUBFRAME _N M12x1,5x80 80 Nm _N M12X1,5x Nm _N M12x1,5 120 Nm _N M10X35 80 Nm (1) VN M12x1,5x Nm (1) (2) VN M12X Nm (2) _WHT ECCENTRIC BOLT M12X1,5X Nm V3FL V3FL511407A ANTIROLL BAR Ø 22x3 ANTIROLL BAR Ø 22x4 (OPTION) DISTANCE BETWEEN CENTERS = 114 mm. VN M10X40 40 Nm VN M8X50 40 Nm PUT A DROP OF GREASE ON THE FRICTION ZONE CHECK THAT THE ANTI ROLL BAR IS FREE AFTER TIGHTENING 20

21 PEDAL BOX PRODUCTION SET UP DISTANCE: 36 mm. PRODUCTION SET UP DISTANCE: 35,2 mm. PRODUCTION SET UP DISTANCE: 34 mm. STANDARD MECHANICAL STOPPER LENGTH: 11,8 mm. Keep clean the axle thread and the unibal and do not lubricate. The gap on both sides must be at least 2,5 mm to allow the system to work properly. 21

22 FRONT & REAR END _N HEX. HEAD BOLT M10x35 60 Nm _N HEX. HEAD BOLT M8x25 25 Nm 22

23 BACKET SEAT VN M8x25 25 Nm 23

24 BALLAST FIXATION In the event that any car needs to add some extra weight, there are different shapes and sizes to be combined between them. They are detailed here below: 5F KG BALLAST 5F A 3 KG BALLAST 5F H 5 KG 5F J 10 KG 5F K 20 KG 5, 10 & 20 KG SQUARED BALLAST 5F L 5 KG 5F M 10 KG 5F N 20 KG 5, 10 & 20 KG ADVANCED BALLAST The Advanced Ballast solution allows to put the weight in position closer to the front of the car. In order to make a safe assembly, M8 bolts with a minimum of 12 mm thread depth is recommended. The picture shows how to fix the Advanced ballast to the car. 24

25 DSG GEARBOX _N HEX HEAD BOLT M10x110x70 60Nm _N TORX HEAD BOLT M6x20 16 Nm 25

26 DSG GEARBOX _N HEX. HEAD BOLT M12x55 80 Nm _N HEX. HEAD BOLT M10x45 60 Nm _N DOUBLE THREAD BOLT M10X40 - M8X16 60 Nm _N HEX. HEAD BOLT M12x65 80 Nm _N HEX. HEAD BOLT M12x70 80 Nm _N HEX. HEAD BOLT M10x50 60 Nm 26