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Technical manual
This user manual is intended to be a guide for the understanding of the Ibiza SC Trophy
manufactured by SEAT Sport S.A.
For any questions queries or suggestions, please contact the vehicle manufacturer:
Salesperson concerned
Xavier Carrasquilla
Tel. +34 93 774 1875
Fax. +34 93 773 3410
javier.carrasquilla@seat.es
Any questions or queries should be referred to the salesperson concerned, who will pass on the
notice to those in charge of the different departments.
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IBIZA SC TROPHY
Technical manual
1. Introduction
The SEAT Ibiza SC Trophy is a vehicle developed by SEAT Sport, based on the new SEAT
Ibiza Cupra model, continuing in the vein of the successful competition vehicles developed by the
SEAT brand.
The main technological innovations developed by SEAT Sport for the new SEAT Ibiza SC
Trophy are:
Inclusion for the first time in competition of a direct injection Bi-turbo engine.
Adaptation for the first time in competition of the new DSG 7 speed gearbox, evolved by
SEAT Sport for competition.
The diagnosis and alarm system on the instrument panel has been maintained, combined
with the possibility of a dashboard with data collection.
With the new SEAT Ibiza SC Trophy the engine and gearbox management systems have been
maintained and increased in production that has given such good results to the brand, maintaining
commitment to costs and customer loyalty that reinforces the school spirit and bringing their services
closer to passenger vehicle categories.
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IBIZA SC TROPHY
Technical manual
0. CONTENTS
1.
Introduction ............................................................................................................. 3
0.
CONTENTS ............................................................................................................. 4
2.
General characteristics............................................................................................ 5
3.
Engine ...................................................................................................................... 6
3.1.
Presentation ......................................................................................................................... 6
3.2.
Engine Technical Data ......................................................................................................... 6
3.3.
Main elements of the engine ................................................................................................ 6
3.3.1.
Overpressure circuit ..................................................................................................... 6
3.3.2.
Turbocharger ................................................................................................................ 7
3.3.3.
Compressor .................................................................................................................. 7
3.3.4.
Charge air cooler .......................................................................................................... 8
3.3.5.
Oil circuit. ...................................................................................................................... 8
3.3.6.
Bicircuit refrigerant system. .......................................................................................... 9
3.3.7.
Regulated fuel system ................................................................................................ 10
3.4.
Engine control..................................................................................................................... 12
4.
Gearbox .................................................................................................................. 16
4.1.
Presentation ....................................................................................................................... 16
4.2.
Technical characteristics .................................................................................................... 16
4.3.
Main elements .................................................................................................................... 16
4.3.1.
Clutch.......................................................................................................................... 16
4.3.2.
Drive shaft .................................................................................................................. 17
4.3.3.
Mechatronic moduleM ................................................................................................ 17
4.4.
Operation............................................................................................................................ 17
5.
6.
Presentation ....................................................................................................................... 19
Front axle............................................................................................................................ 19
Rear axle ............................................................................................................................ 20
7.
8.
Body........................................................................................................................ 22
8.1.
9.
Certification......................................................................................................................... 22
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IBIZA SC TROPHY
Technical manual
2. General characteristics
Engine
Type
Power supply system
Displacement (cc)
Bore and stroke (mm)
Maximum power (hp/rpm)
Maximum torque (Nm/ rpm)
Exhaust / dB.
Fuel
Fuel consumption
Fuel tank
Power transmission
Traction
Gearbox
Differential
Clutch
Gearbox control
Suspension and brakes
Front suspension
Front stabiliser
Rear suspension
Brake
Front brakes
Rear brakes
Steering system
Rims
Tires
Diagnosis
ECU Engine
Diagnosis system
Chassis and aerodynamics
Weight
Aerodynamics
Front width (max)
Rear width (max)
Height
Wheelbase
Optional
Data collection
Airjack
Transponder
Auxiliary 12v socket
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IBIZA SC TROPHY
Technical manual
3. Engine
3.1.
Presentation
The Ibiza SC Trophy has a 1.4L direct injection petrol
engine with twin supercharger.
The power is achieved due to the Motronic MED
17.5.5 engine control.
The main new element of this engine is the
incorporation of a compressor in the turbocharger
additional air overpressure circuit.
The combination of the compressor and the
turbocharger optimises the engine performance at all
engine speeds, supplying a high torque value from low
revolutions.
The 1.4L TSI engine with twin supercharger presents the following characteristics:
- Timing chain system free from maintenance.
- Variable intake valve timing.
- Lubrication circuit with duo-centric pump activated by an independent chain.
- Twin supercharger using a compressor activated by belt and the turbocharger activated by exhaust
gases.
- The cooling circuit with double thermostat, one for the block and another for the cylinder head.
- The air-air charge air cooler is situated at the vehicle front end.
- Turbocharger with greater dimensions.
- And new engine control.
3.2.
3.3.
3.3.1.
Overpressure circuit
The main elements that make up the engine overpressure circuit are:
- A compressor
- A regulating flap.
- A turbocharger.
- And a charge air cooler.
The compressor is activated by a Poly-V belt and is switched off and on with a magnetic coupling,
N241, controlled by the engine control unit.
The regulating flap is situated in a circuit parallel to the compressor and is controlled by the engine
control unit in order to regulate the pressure generated by the compressor via the control motor
V380.
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IBIZA SC TROPHY
Technical manual
The turbocharger is of fixed geometry and is activated by the exhaust gases. The engine control
unit regulates the pressure generated by the turbocharger using the solenoid valve for charge
pressure control, N75. The air recirculation solenoid valve is located in the turbocharger N249.
The charge air cooler is situated in the front end part of the engine compartment next to the liquid
coolant radiator.
3.3.2.
Turbocharger
The turbocharger is oversized with
respect to its use in the 1.4L TSI
engine without twin supercharger.
The largest size of turbocharger allows
performance optimisation at high engine
speeds.
It forms a compact assembly with the
exhaust manifold and is manufactured in
heat-resistant casting.
It is a fixed geometry turbocharger, and
is connected to the engine cooling and
lubrication circuit for the cooling and
lubrication of the blower shaft.
The maximum blower temperature is
limited by a pneumatic control element,
controlled by the solenoid valve for
charge pressure control, N75.
The air recirculation valve, N249, is
integrated in the turbocharger housing in
order to prevent the blower from braking
during engine deceleration.
3.3.3.
Compressor
The compressor is bolted to the block below the throttle selector unit.
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IBIZA SC TROPHY
Technical manual
3.3.4.
Charge air cooler
The charge air cooler is situated in the lower part
of the vehicle front end, in front of the liquid
coolant radiator.
The air first circulates through the compressor and
then through the turbocharger. At the output of the
turbocharger the air temperature can reach 200
C.
To reduce this high value of air exiting the turbocharger the air circulates through the charge air
cooler where it is cooled.
3.3.5.
Oil circuit.
Oil circuit
The oil circuit includes the cooling of the exhaust
turbocharger and the cooling of the pistons.
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IBIZA SC TROPHY
Technical manual
Colour legend
Oil vacuum
Oil supply
Oil return
3.3.6.
This is a bicircuit system with divided liquid coolant conduction that has different temperatures
caused by the block and the cylinder head.
The liquid coolant is conducted through the cylinder head from the exhaust side to the intake side.
This produces even temperatures in the cylinder head. This schema is denominated a cooling circuit
by transverse flow.
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IBIZA SC TROPHY
Technical manual
The refrigerant system is divided into two circuits in the engine. Approximately a third of the engine
liquid coolant flows towards the cylinders and two thirds flow towards the combustion chamber areas
in the cylinder head.
3.3.7.
Regulated fuel system
The fuel system is regulated as necessary. The advantage is that both the electrical fuel pump and
the high-pressure pump only raise the fuel quantity to the amount needed in the engine at a given
moment. This reduces the power consumed by the fuel pumps and saves fuel.
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Technical manual
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Technical manual
3.4.
Engine control.
Engine control is carried out using the information sent by the sensors situated in the engine and the
different components that surround it.
Unit / Sensor
The engine
control unit
J823
Intake pressure
sensor G71 +
intake air
temperature
G42
Pressure
sensor on the
intake manifold
(compressor)
G583 with air
intake
temperature
sensor G520
Charge
pressure sensor
G31 With
intake air
temperature
sensor 2 G299
Environment
pressure sensor
Application of the
signal
Engine control +
charge pressure
control
With the help of these
signals and the engine
speed signal the
engine control unit
calculates the air
intake mass.
Charge pressure
control for the
compressor using the
regulating throttle
selector unit. The
temperature sensor
signal of the intake air
is also used to protect
components against
the effects of
excessive
temperatures. As of
130 C the compressor
power is reduced.
Effect of absence of
signal
Does not start.
Position
Engine compartment
Close to
the throttle selector unit in the
charge air pipe.
If there is a fault in
the environment
pressure sensor, the
turbocharger will only
work in a controlled
manner.
This may produce
greater emissions
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IBIZA SC TROPHY
Technical manual
Engine speed
sensor G28
The moment
calculated for injection,
the injection duration
and the moment of
ignition are determined
by this signal.
Likewise, it is used for
camshaft adjustment.
Throttle valve
selector unit
J338 with angle
sender for the
throttle control
G187 and G188
Regulating
throttle selector
unit J808
Potentiometer
for regulating
throttle G584
Accelerator
pedal position
sensors G79
and G185
,
In the ECU
If there is a fault in
the sensor the engine
continues to operate.
However, further
starting of the vehicle
is no longer possible.
The camshaft
adjustment is
deactivated and the
inlet camshaft
remains in the "delay
position". A loss of
torque is produced.
If there is a fault in
both sensors the
throttle control is
deactivated and
engine speed is
limited to 1,500 rpm.
Fault in a sensor
If there is a fault in a
sensor, the system
firstly enforces idling
speed. If, after a
specified time for
verification of the
idling position, the
second sensor signal
is detected the
vehicle will once
again be able to run.
If the driver orders full
charge delivery the
system will only
slowly increase
speed.
Fault in both sensors
If there is a fault in
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IBIZA SC TROPHY
Technical manual
Brake pedal
position sensor
G100
Fuel pressure
sender G247
Knock sensor
G61
If a detonating fuel is
detected the ignition
angle is adjusted in the
affected cylinder until
the knocking ceases to
occur.
Liquid coolant
temperature
sensor -G62-
IBIZA SC TROPHY
Technical manual
Lambda probe
G39 with
heating of
lambda probe
Z19
Throttle
potentiometer
on the intake
manifold G336
Sensor for
current
measurement
G582
The development of
the intensity of the
current is no longer
detectable and the
electromagnetic
coupling switches on
in a mode adverse to
convenience.
Post catalytic
converter
Lambda probe
G130 with
heating of
lambda probe
Z29
Operation values:
Next, the engine operation values are shown:
CHANNEL
Engine speed
NOMINAL
MINIUM VALUE
MAXIMUM
VALUE
idling
1170 rpm
7000 rpm
Turbo pressure
2 bar
1 bar
2.5 bar
Compressor pressure
2 bar
1 bar
2.5 bar
Modulated PWM
0.5 bar
6.5 bar
Modulated PWM
50 bar
150 bar
2.5 bar
1.5 bar
4.5 bar
Oil pressure
T cylinder head liquid coolant
T1- 80 C
105 C
T2- 95 C
105 C
T intake air
65 C
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IBIZA SC TROPHY
Technical manual
4. Gearbox
4.1.
Presentation
The Ibiza SC Circuit applies dual clutch technology. The new DSG 7 gears offers various
simultaneous innovations.
Structural characteristics:
gearbox modular design:
oil system separated by the
mechatronic and manual gearbox.
7 gears distributed between 4
camshafts
oil pump that functions according
to demand.
no oil/water heat exchanger
4.2.
Technical characteristics
4.3.
Main elements
4.3.1.
Clutch
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IBIZA SC TROPHY
Technical manual
4.3.2.
Drive shaft
The Ibiza SC Circuit has, opposed to the series Ibiza, an intermediate semi-axle on the right side. As
a result, the drive shafts are equal in length on each side. This advantage allows the chassis
temperature to be lowered improving the centre of gravity.
4.3.3.
Mechatronic moduleM
4.4.
Operation
N - Neutral
SYSTEM
In order to move the selector lever from this
position the ignition must be switched on and
the brake pedal pressed down.
In order to engage this gear the release tab
must be pressed.
The gear is situated in dead centre.
S - Sport
P - Park
R - Reverse gear
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Technical manual
5.1.
Unit / Sensor
STEERING WHEEL
ROTATIONAL
SPEED SIGNAL
Application of the
signal
The electro-hydraulic
power steering control
unit uses the steering
system angle sender
G85 to recognise the
steering wheel
rotational speed.
This is used in the oil
pressure regulating
function.
Effect of absence of
signal
Position
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IBIZA SC TROPHY
Technical manual
SPEED SIGNAL
SPEED SIGNAL
The electro-hydraulic
power steering
control unit uses this
message as an
essential signal in the
steering system
regulation function.
Presentation
In the Ibiza SC Circuit the series dimensions have been modified and some elements, flexible for
adaptation to sport driving, have been eliminated.
6.2.
Front axle
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IBIZA SC TROPHY
Technical manual
6.3.
Rear axle
Rigid torsional strut with integrated support arm.
Shock absorber with height adjustment and integrated springs.
Camber and convergence spacers.
Mono-block brake caliper and discs 288x12 mm.
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IBIZA SC TROPHY
Technical manual
7. Suspension adjustment
CONFIGURATION
Main spring
Available range
Available range
Tender
MAX fitted length
Shock absorber limit
Compression spacer
Stabiliser
Wheel
Tyre pressure hot
Brake pads
Wing
FRONT shaft
160-60-70N/mm
REAR shaft
180-60-90N/mm
160-60-70N/mm
180-60-80N/mm
160-60-80N/mm
180-60-90N/mm
60-60-2
60-60-2
With 160-60-70=185
With 160-60-80=240
With 160-60-80=188
With 160-60-90=242
Koni std =
5mm
20 N/mm
17x7.5/ET42
Manufacturer
Championship
No
NO
5mm
15N/mm
17x7.5/ET42
Manufacturer
Championship
Low downforce
ALIGNMENT
Left
4.5
1.5 mm OUT
Camber
Convergence
FRONT
Right
4.5
1.5 mm OUT
REAR
Camber
Convergence
2.5
4.0 mm Open
Camb
er
From 3.5 to 5
Each position is 0.5 approx
Camb
er
Fixed (See powerparts)
2.5
4.0 mm Open
Front
Rear
Front
Rear
378,8
195,2
Total
66,0%
34,0%
Front
Rear
378,8
195,2
1148,0
Diag
Left
50,0%
50,00%
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IBIZA SC TROPHY
Technical manual
8. Body
The bodywork has been modified to adapt to the needs of motor sport use. The most relevant
characteristics are:
8.1.
Certification
The bodywork with roll bar, designed and manufactured by SEAT Sport has a certification number
from the Spanish Automobile Federation (R.F.E.A.):
Certification No. R.F.E.A.:
HES4260211
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IBIZA SC TROPHY
Technical manual
Dimensions:
9. On board network
The SEAT Ibiza SC Trophy is a competition vehicle, constructed 100% by hand at SEAT Sport, the
VAS diagnostic system has been maintained as the electronic unit management. This point has
special importance due to the fact that the DIAGNOTIC functions are guided using the VW group
VAS system.
The main new elements:
The incorporation of network Gateway. The
Gateway or BCM performs the functions of
converter, processor and controller of the
CAN-Bus and LIN-Bus.
The immobiliser system remains, however,
its transponder has a hidden key, and
maintains start-up using a switch and button.
The diagnostic system and alarm on the
instrument panel remain.
A data collection system connected to the
CAN has been added (optional), that
provides the opportunity of improving the car
set up based on technical data.
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IBIZA SC TROPHY
Technical manual
9.1.
Self-diagnosis
9.2.
On board network
In the address code 09 a drop down menu opens where it is possible to select the option "J519 on
board supply control unit, functions". Here we find, among others, the following functions:
- Coding.
- Adaptation
- Read measured value blocks.
On the following pages of this didactic book these functions are detailed one-by-one.
9.2.1.
Coding
The on board supply control unit incorporates the long codification due to the large quantity
of functions that can be configured through codification. In this manner, the code itself is a
programme matrix composed of 27 bytes, and in addition, each of the bits that compose it (1 or 0) is
assigned to equipment or a function.
The coding is carried out whenever the unit is replaced. Before removing the unit, note down the
code to re-enter again in the new unit.
With every SEAT Sport vehicle delivery a module coding sheet is provided. It is also possible to note
down the coding by consulting the vehicle diagnostic system using the tool VAS 5052
9.2.2.
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IBIZA SC TROPHY
Technical manual
10. Maintenance
MAINTENANCE
NAME
Every
race
DIAGNOSIS
VAS Engine
VAS Gearbox
VAS CAN Bus
Data Logger
ENGINE
Complete engine
Spark plugs
Air cleaner
Poly V-belt
Engine oil
Engine oil filter
Fuel filter
Gearbox
Complete gearbox
Drive shaft
SDF
Shock absorber
Wheel bearings
Steering ball joint
Trapezium link ball joints
Front shock abs. sup. ball
joint
Rear shock abs. sup.
Wheel nuts
Safety
Extinguisher
Every
Every
Every
2,500 km 5,000 km 10,000 km
COMMENTS
Rev.
Rev.
Rev.
Rev.
Rev.
Rev.
Rev.
Repl.
Repl.
Rev.
Repl.
Repl.
Repl.
Repl.
Rev.
Rev.
Replace grease
Repl.
Repl.
Repl.
Repl.
Repl.
Repl.
Repl.
Expires
years
Expires
years
Expires
years
Bucket seat
Harness
after
after
after
CAPACITIES
Name
Engine oil
Capacity
5.5 litres (with filter)
Gearbox oil
Mechatronic oil
1.7 l
1.0 l
Description
Castrol
Edge
10/60
G 052 171
G 004 000 M2
1.5 litres
6.5 litres
G 004 000 M2
VW Group "blue"
1 litre
100 grams
Motul 600
GKN
Constant
velocity
GKN Tripod
100 grams
Recommendations
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IBIZA SC TROPHY
Technical manual
11. Seals
On the SEAT Ibiza SC Trophy made by SEAT Sport, a series of parts have been presealed with the
aim of ensuring the traceability and authenticity of the parts.
Engine: 2 seals.
Distribution/cylinder head
Turbo
Gearbox. 1 seal
Differential/pinions
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Technical manual
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IBIZA SC TROPHY