Hyundai I30 TCR - Manual - Edition6

Hyundai i30 N TCR
i30 N TCR
USER MANUAL
Hyundai i30 N TCR
1. CONTACT INFORMATION ..................................................................................................................... 5
2. TECHNICAL INFORMATION .................................................................................................................. 6
2.1. General car data .................................................................................................................................. 6

2.2. Dimensions and weight ...................................................................................................................... 7
3. WORKSHOP MAINTENANCE ................................................................................................................ 8
3.1. Engine ................................................................................................................................................... 8

3.1.1. Engine Control System .............................................................................................................. 8
3.1.2. Engine Oil Maintenance .......................................................................................................... 10
3.2. Waste gate valves ............................................................................................................................. 11
3.3. Air filter ............................................................................................................................................... 12
3.4. Gearbox .............................................................................................................................................. 15
3.4.1. Gear Maintenance .................................................................................................................... 15
3.4.2. Gear Cluster and Diff Setup .................................................................................................... 15
3.4.3. Mainshaft Reverse hub ............................................................................................................ 16
3.4.4. Selector Barrel Setup ............................................................................................................... 16
3.4.5. Ratio Change............................................................................................................................. 16
3.5. Differential ......................................................................................................................................... 18
3.5.1. Differential Stack Height and Preload ................................................................................... 18
3.5.2. Differential settings .................................................................................................................. 19
3.5.3. Pre-load Setting ........................................................................................................................ 21
3.5.4. Pre-load Checking Process ..................................................................................................... 22
3.5.5. Differential Characteristics ..................................................................................................... 22
3.6. Clutch ................................................................................................................................................. 24
3.6.1. Clutch Specification ................................................................................................................. 24
3.6.2. Clutch Maintenance ................................................................................................................. 24
3.7. Brakes ................................................................................................................................................. 25
3.7.1. Brake Configurations ............................................................................................................... 25
3.7.2. Brake Pads Friction Specification........................................................................................... 26
3.7.3. Brake Bedding in Process ........................................................................................................ 27
3.7.4. Rear Brake Pressure Limiter (Proportioning Valve) ............................................................. 28
3.7.5. Brake balance ........................................................................................................................... 29
3.8. Lifting System .................................................................................................................................... 30
3.8.1. Air Jack Specification .............................................................................................................. 30
3.8.2. Air Jack Maintenance .............................................................................................................. 30
3.8.3. Air Jack Connector ................................................................................................................... 30
3.9. Fuel Tank ............................................................................................................................................ 31
3.9.1. Fuel Tank Specification............................................................................................................ 31
3.9.2. Refuelling - Sprint .................................................................................................................... 31
3.9.3. Defueling ................................................................................................................................... 32
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3.10. Headlights .......................................................................................................................................... 33

3.10.1. Headlight Replacement ........................................................................................................... 33
3.10.2. Headlight bulb replacement ................................................................................................... 33
3.11. Brake Quick Release Connector ...................................................................................................... 34
3.12. Torque & Loctite Settings ................................................................................................................ 35
3.12.1. Engine Assembly ...................................................................................................................... 35
3.12.2. Gearbox & Drive Train Assembly ............................................................................................ 38
3.12.3. Chassis Assembly ..................................................................................................................... 39
3.12.4. Front Suspension Assembly .................................................................................................... 40
3.12.5. Rear Suspension Assembly ..................................................................................................... 42
3.12.6. Steering Assembly .................................................................................................................... 44
3.12.7. General Tightening Torque ..................................................................................................... 45
3.13. Fluids................................................................................................................................................... 46
3.14. Identifications .................................................................................................................................... 47
3.14.1. Chassis number ........................................................................................................................ 47
3.14.2. Engine sealing number ............................................................................................................ 47
4. CONTROLS ........................................................................................................................................... 48
4.1. Switch Panel ...................................................................................................................................... 48

4.2. Steering Wheel .................................................................................................................................. 49
4.2.1. Steering Wheel Switch Panel .................................................................................................. 49
5. ELECTRONICS ...................................................................................................................................... 51
5.1. Dash Keypad ...................................................................................................................................... 51

5.1.1. Drivers Menu ............................................................................................................................. 51
5.2. Drivers Display ................................................................................................................................... 53
5.3. Launch Start ....................................................................................................................................... 57
5.3.1. Launch Start Procedure ........................................................................................................... 57
5.4. Software Installation ......................................................................................................................... 58
5.5. Connect and down load – Life Data ............................................................................................... 62
5.5.1. Introduction .............................................................................................................................. 62
5.5.2. Log Screen................................................................................................................................. 62
5.5.3. Log Screen................................................................................................................................. 63
5.5.4. Autoread .................................................................................................................................... 65
5.5.5. Read ........................................................................................................................................... 67
5.5.6. Stream........................................................................................................................................ 67
5.5.7. Comments ................................................................................................................................. 68
5.5.8. Decode .LRS .............................................................................................................................. 68
5.5.9. Quick View................................................................................................................................. 68
5.5.10. Global Option ............................................................................................................................ 68
5.6. Open and Read Data - LifeView ...................................................................................................... 69
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5.6.1. Instruction ................................................................................................................................. 69

5.6.2. Files – Load / Import ................................................................................................................ 69
5.6.3. Files – Save / Export ................................................................................................................. 71
5.6.4. Graph ......................................................................................................................................... 72
5.6.5. Navigation ................................................................................................................................. 72
5.6.6. Channels .................................................................................................................................... 73
5.6.7. Math ........................................................................................................................................... 75
5.6.8. Lap Mode ................................................................................................................................... 77
5.6.9. Multiple Files ............................................................................................................................. 77
5.6.10. Worksheet ................................................................................................................................. 78
5.6.11. Workbooks ................................................................................................................................ 78
5.6.12. Graphs ........................................................................................................................................ 79
5.6.13. Reports ...................................................................................................................................... 79
5.6.14. Track Map .................................................................................................................................. 82
5.6.15. Floating Windows ..................................................................................................................... 84
5.6.16. Session ....................................................................................................................................... 85
5.6.17. Toggle Option ........................................................................................................................... 86
5.6.18. Cursor Options .......................................................................................................................... 87
5.6.19. Concatenated File Options ..................................................................................................... 87
5.6.20. Global Options .......................................................................................................................... 87
5.7. Logging channel List ......................................................................................................................... 89
5.8. Trip levels in limp mode ................................................................................................................... 94
5.9. Engine fire up..................................................................................................................................... 95
5.9.1. Engine fire up procedure ......................................................................................................... 95
5.9.2. Vital Parameter to Check......................................................................................................... 95
5.10. Extra Connectors ............................................................................................................................... 96
5.11. Gearbox Error Code .......................................................................................................................... 99
6. SETUP ADJUSTMENTS ...................................................................................................................... 100
6.1. Setup sheet (base setup on delivery) ........................................................................................... 100

6.2. Ride height adjustments ................................................................................................................ 102
6.2.1. Ride height measuring point ................................................................................................ 102
6.3. Dampers ........................................................................................................................................... 103
6.3.1. Damper setting ....................................................................................................................... 103
6.4. Anti-roll bars .................................................................................................................................... 111
6.4.1. Anti-roll Bar Adjustment ........................................................................................................ 111
6.5. Alignment ......................................................................................................................................... 113
6.5.1. Camber .................................................................................................................................... 113
6.6. Suspension Geometry .................................................................................................................... 114
6.7. Aerodynamics .................................................................................................................................. 116
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6.7.1. Aerodynamic Adjustment...................................................................................................... 116

6.7.2. Aerodynamic Setting Effect .................................................................................................. 117
7. TOOLING ............................................................................................................................................ 118
7.1. Alignment tool ................................................................................................................................. 118

7.2. Gearbox tool .................................................................................................................................... 119
8. LIFING ................................................................................................................................................. 120
9. ATTACHMENTS .................................................................................................................................. 122
9.1. TCR Technical Form order procedure .......................................................................................... 122

9.2. Gearbox Drawings ........................................................................................................................... 124
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1. CONTACT INFORMATION
Car Sales & Commercial Enquiries

Name E-mail Phone Number
Andrew Johns ajohns@hyundai-ms.com +49 (0) 6023 9929 431
Veronica Boni vboni@hyundai-ms.com +49 (0) 6023 9929 434

Spare Part Sales
Timo Hadzibeganovic thadzibeganovic@hyundai-ms.com +49 (0) 6023 9929 437
Federico Lancini FLancini@hyundai-ms.com +49 (0) 6023 9929 436

Engineering Support – Chassis / Mechanical
Andrea Cisotti acisotti@hyundai-ms.com +49 (0) 6023 9929 457
Jihun Park jhpark@hyundai-ms.com +49 (0) 6023 9929 438
Nicolas Schwartz nschwartz@hyundai-ms.com +49 (0) 6023 9929 432
Miguel Freitas mfreitas@hyundai-ms.com +49 (0) 6023 9929 429

Engineering Support – Engine / Electronical
Andrea Maselli amaselli@hyundai-ms.com +49 (0) 6023 9929 433
Joseph Hunt jhunt@hyundai-ms.com +49 (0) 151 6495 6274

FTP site access
URL https://ftp.hyundai-europe.com/
TCR username HMSGCTCR
TCR password CustomerRacing-TCR

Addresses
Hyundai Motorsport GmbH, Carl Zeiss Strasse 4,
Reception
63755 Alzenau, Germany
Hyundai Motorsport GmbH, Junker Strasse,

Stores
63755 Alzenau, Germany
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2. TECHNICAL INFORMATION
2.1. General car data
Engine
Type Turbocharged & Direct injection
Engine identification THETA II T-GDI (G4KH)
Cylinder capacity 1999,6 cm3
Bore & stroke 86,0mm x 86,0mm
Maximum rpm 7000 rpm
Electronic control unit Liferacing engine management system
Fuel tank capacity 100 litres
Oil system Wet Sump

Transmission
Gearbox Xtrac 6 speed sequential
Differential Salisbury plate type with adjustable external preload
Shifter Pneumatic paddle shift on steering wheel
Clutch AP racing hydraulic 2 plates clutch

Suspension
Suspension type (Front / Rear) McPherson strut / 4 links
Damper 2-way adjustable, ride height adjustable
Anti-roll bar Roll stiffness adjustable (Soft / Medium / Hard)

Brake
Brake Calipers (Front / Rear) Brembo bespoke 6-piston / Brembo 2-piston
Disc (Front / Rear) Brembo Ø380mm ventilated / Brembo Ø 278mm ventilated
Brake pads Pagid brake pads
Brake balance Front & rear brake balance adjustable
Pedal system Hyundai Motorsport bespoke pedal system
Hand brake Hydraulic handbrake with mechanical locking
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2.2. Dimensions and weight
Dimensions
Overall length 4668 ±10 mm
Wheelbase 2678 ±10 mm
Overhang front 957 ±10 mm
Overhang front bumper 932 ±10 mm
Overhang rear 1033 ±10 mm
Overhang rear bumper 832 ±10 mm
Overall bodywork width 1950 -1,0 %
Ride height Depending on latest BoP

Weight
Minimum weight 1265kg, depending on latest BoP
Figure 1. Dimension
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3. WORKSHOP MAINTENANCE
3.1. Engine
3.1.1. Engine Control System
List Of Engine Control System Sensors

No Qty Function Make Reference
C1 1 Intake Camshaft Position Hyundai Motors 39350-2G000
C2 1 Engine Speed Hyundai Motors 39180-2G000
C3 1 Engine Coolant Pressure & Temperature Hyundai Motors 94750-2A000
C4 1 Engine Oil Pressure & Temperature Hyundai Motors 94750-2A000
C5 1 Fuel Low Pressure & Temperature Hyundai Motors 94750-2A000
C6 1 Fuel High Pressure Hyundai Motors 35342-2GGA0
C7 1 Exhaust Gas Temperature Hyundai Motors 99518-5G0
C8 1 Lambda Hyundai Motors 18200-00100
C9 1 Gearbox Oil Temperature Hyundai Motors 18212-00100
C10 1 Barometric Air Pressure & Temperature Hyundai Motors 99516-5G0
C11 1 Inlet Port Pressure & Temperature Hyundai Motors 39300-4A800
C12 1 Manifold Absolute Pressure Hyundai Motors 39300-84400
C13 2 Knocking Hyundai Motors 39250-2G700
C14 1 Throttle Pedal Position Hyundai Motors 99521-5G0
C15 1 Intake Camshaft Position Hyundai Motors 39350-2G000
List Of Engine Control System Sensors
No Qty Function Make Reference
A1 1 Electric Throttle Hyundai Motors 28401-TS0
A2 4 Coils Hyundai Motors 27301-5G0
A3 4 Spark Plugs Hyundai Motors 27200-TS0
A4 4 Fuel Injectors Hyundai Motors 31400-TS0
A5 1 Wastegate Valve Loom Hyundai Motors 39401-5G0
A6 1 Variable Valve Timing Actuator (Intake) Hyundai Motors 24360-2GGB0
A7 1 Variable Valve Timing Actuator (Exhaust) Hyundai Motors 24375-2G500
A8 1 High Pressure Fuel Pump Hyundai Motors 35320-2GTA0
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Location Of Sensors And Actuators
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3.1.2. Engine Oil Maintenance
Filling And Draining The Oil
 Fill the engine with Shell Helix

Racing 0W-40 engine oil, via
filler hole in the cam cover
 Always check the level with

the dipstick after filling
 Drain the oil via the oil plug in

the sump, using a 17mm
socket.
 Always replace the seal, and

tightening torque to 30Nm
Checking The Oil Level
 Always fill the oil to the

maximum level mark, on the
dipstick
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3.2. Waste gate valves
Fitting Valves To Waste Gate
 Waste gate 1 is ‘red’ and Waste

gate 2 is ‘blue’.
 Please connect the waste gate

valves as in the picture.
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Hyundai i30 N TCR
3.3. Air filter
Flow Direction Of The Air Filter
Air Filter Cleaning Procedure (Pictures Are Only For Illustration)
 Remove the filter and tap it gently on a solid surface in order to

remove the biggest impurities (such as grass, gravel and bugs)
and clean the air-box.
 Be careful not to damage the filtering element. Do not use
compressed air because it will damage the filtering element.
 Lay down the filter on a container and distribute one-half of

detergent bottles on it.
 Apply the detergent on the filter and wait around 20/30

minutes, meanwhile the product acts.
 Wash the filter using the water hose, provided with jet
regulation accessories. Rinse it well on both sides until the
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Hyundai i30 N TCR
filter is clean. Check backlights the absence of impurities. Bear

in mind that the filtering material will not be perfectly white
but it must be free of impurities.
 Use the bowl only for containing the dirty water and do not
place the filter into it, to avoid soiling it. The dirty water must
be deposed into the specific recycling depot. If the filter is not
clean enough, please repeat the operations above described.
 Do not use high pressure.
 Let the filter dry naturally out door without exposing it directly
to the sunlight. The filter will be dry once it will release neither
water nor humidity. This could be checked by using
compressed air, softly and from a precautious distance in order
not to damage the cotton texture.
 Do not use compressed air.
Bottle Re-Oiling
 It is important to use the correct quantity of oil. Too much oil could damage the debimeter and not
enough oil could provide les protection to the engine.
 Cut off the spout dispenser in a “v” shape and screw it into the
bottle. Put the spout on the first pleat, apply a small pressure
on the case and start the re-oiling process. The re-oiling must
be done only on one side of the filter. In order to avoid the
accumulation of oil, it is recommended to perform the action
uninterruptedly.
 Let the filter to totally assimilate the oil. This can be verified by
checking the homogeneity of the red colour on both sides of
the filter.
 Remove the oil surplus tamponing the filter with a clean cotton
cloth.
Spray Re-Oiling
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 Homogeneously apply the nebulized oil on both sides of the

filtering element from a 15 cm distance.
 After these steps are executed, the filter can be immediately

reassembled.
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Hyundai i30 N TCR
3.4. Gearbox
Six hobbed gears have optimised tooth width. The gears are spaced on 89,48mm centres, with 1st
gear integrated into the layshaft.
Gear Ratio
Gear Z1 Z2 Gear ratio Max. RPM Max. Speed*
st
1 13 35 2,692 7000 97 km
nd
2 14 29 2,071 7000 126 km
rd
3 18 30 1,666 7000 157 km
th
4 18 25 1,388 7000 189 km
th
5 18 21 1,166 7000 225 km
th
6 24 24 1,000 7000 262 km
Reverse 2,187
Final drive 13 42 3.230
* Max speed is theoretical speed
3.4.1. Gear Maintenance

Lint free cloths are recommended for wiping down internals. If paper tissue is used, care must be
taken to ensure fibres are not left behind which will result in a blocked oil filter.
All joint faces are sealed with O-rings, Silicon sealant MUST NOT be used anywhere on the gearbox, as
excess sealant can enter the oil system and clog the filter or oil jets around the gearbox. This will lead
to premature failure of the transmission.
Since bearings have press fit tolerances, always heat the casings for the fitment or removal of bearings
to avoid damage to the bearings or casings. Do not heat the gearbox casings above 135 °C
Loctite Usage
Loctite 270 All studs fitted into casings
For high temperature retaining of parts with a clearance or interference fit i.e.
Loctite 648
retaining bushes, bearings, seals
Rapid bonding of rubbers when used with Loctite 7239 Polyolefin Primer bonds
Loctite 406
Used for O-ring sealing and bonding
Loctite 571 For the locking and sealing of metal tapered threads and fittings
3.4.2. Gear Cluster and Diff Setup

The cluster and diff is assembled using the drawings found in ‘Attachments’ and the following
instructions.
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3.4.3. Mainshaft Reverse hub

The mainshaft components are locked by the reverse hub and held with a locking shaft. The thread
should be oiled and the torque setting on the drawing should be adhered to. The hub can be ‘backed
off’ should the alignment of the locking shaft need adjustment.
3.4.4. Selector Barrel Setup

The tolerance stack up on individual parts across the assembly can affect the alignment of the dog
rings. The barrel should therefore be shimmed to ensure it holds the selector forks and dog rings
central to the dogs of the gear cluster gears. The alignment needs to be checked and altered when a
new selector barrel or mainshaft assembly is fitted in to the gearbox.
1. Assemble the cluster assembly into the cluster housing assembly and mount in to a vice using the
cluster setting jig assembly shown in drawing 1046-999-002A
2. Rotate the barrel to each ‘in gear’ position and measure the dog stand off using feeler gauges -
Measuring Dog Stand Off. The dog stand off is the distance between each gear dog root and the tip
of the dog ring dog. A small amount of force should be exerted on the fork (at the selector rail
journal) to remove backlash. Dog stand off values are typically 0,05mm to 0.2mm (0,002” to
0,008”).
st th nd th rd th
3. The dog rings reside between pairs of gears (i.e. 1 and 6 , 2 and 4 , 3 and 5 ). If the dog stand
off values are biased toward one end of the cluster then the gear change barrel spacer should be
adjusted to balance these values.
4. After adjusting the gear change barrel spacer (by surface grinding or selecting a larger size) and re-
assembling, check all of the values again to ensure the change was satisfactory.
Please note that the gear change barrel spacer between the two barrel bearings should be ground to
the same size as the casing shoulder between the two bearings upon initial assembly, and hence
requires no further adjustment unless the casing is changed.
3.4.5. Ratio Change

1. Remove the cluster plate from the gearbox, using the jacking threads if required. Remove the snap
ring that holds the layshaft locking ring in place and then remove the locking rings on both layshaft
and mainshaft.
2. Mount the cluster setting plate (shown in 1046-999-002A) in a vice and using the layshaft nut
holding tool and the reversible mainshaft socket slightly loosen the mainshaft reverse hub and
layshaft locking nut.
3. Fit the cluster onto the cluster stand assembly (1046-999-003A). Remove the circlip holding the
selector rail in place, pull out the selector rail and remove by rotating around the mainshaft axis
until all the selector forks are free from the barrel.
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Hyundai i30 N TCR
4. Fully remove the layshaft nut by hand and the mainshaft reverse hub with the mainshaft reverse
gear as a set.
5. Lift the reverse layshaft gear and reverse from the layshaft.
6. Ratios can now be lifted off the mainshaft and layshaft together as a matched set, dog rings and
their hubs can also be lifted off the mainshaft as a set. This can be applied to all gears except first
gear since the layshaft gear is integral.
7. To remove either of the shafts, the cluster plate must be heated to no more than 135oC (275oF) and
the shaft & bearing removed as one.
Ratios can then be swapped / inspected. Reassembly is in the reverse order of points 1 to 7.
Figure 2. Dog drive reference sheet
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3.5. Differential
3.5.1. Differential Stack Height and Preload

1. Assemble all of the differential internals, friction plates, etc. vertically on a flat surface, as shown in
Figure 3 - Section view of the differential assembly. Place a 5-10 kg (11-22lb) weight on top of the
stack to settle the plates and discs, then measure the distance between the mounting face of the
differential end cap and the stepped friction plate at the top of the stack shown as Dimension A in
Figure 3.
2. Measure the distance between the differential casing and stack mounting faces of the differential
end cap shown as Dimension B in Figure 3.
3. Dimension A should be 0,0 - 0,05mm (0 - 0,002”) less than Dimension B, so that there is a 0,0 – 0,05
mm clearance between the plate stack and the differential end cap. Adjust accordingly using
suitable size shim plates. The plates can be ground if the required thickness is between sizes.
4. Assemble the differential end cap and tighten by hand. Fit the differential through the differential
tightening tool and in to the differential holding tool, mounted in a vice. Tighten the end cap using a
½” drive wrench, fitted in the tightening tool, to a torque of 200Nm (148 lbf.ft).
5. Back off the differential cap to the nearest aligned differential body spline tooth, using the window
on the top of the holding tool to view the alignment. Do not over torque the differential cap to
achieve alignment.
6. Mount a differential preload setting tool into a vice and mount the differential cassette on to it,
adjuster side up.
7. Using the second differential preload setting tool, turn the differential over a few times using a
torque wrench. Once the differential feels consistent, measure the turnover torque across the
differential.
8. This value is the preload. This can be adjusted by changing the disc spring or by altering the adjuster
wheel. To change the preload using the adjuster wheel, clamp the differential holding tool in to a
vice and fit the cassette, ensuring the differential cap and body lock together. Using the adjuster
wheel socket, tighten or loosen the adjuster wheel. Re-measure the preload torque and continue to
alter the adjuster wheel accordingly until the desired turn over torque is achieved.
Due to the varying thicknesses and frictional properties of the friction plates and the variation in the
disc spring stiffness throughout the components lives, the preload should be periodically checked and
adjusted. A differential with new friction plates can take up to 500km before the friction plates are
fully bedded in.
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Figure 3. Section view of the differential assembly
3.5.2. Differential settings
The differential is a Salisbury type plate differential, shown in. The side gears are axially supported by
thrust bearings and do not react against any locking part of the differential. The differential is locked
by ramp forces through two symmetrical friction plate packs, giving the differential very linear and
predictable locking forces. The side gear rings (ramps) act against a matching cross pin when torque is
applied across the differential, the side gear pinion mates are free to rotate about the cross pin legs
independently of the ramp forces.
Standard Setting For The Differential

Ramp angle 30/45 ramp angle
Friction faces 8 frictions per side
Preload 85Nm
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Figure 4. Section view of plate differential
Various ramp angles and pre-loads are available, and the number of friction faces in the plate
differential can also be adjusted. 4 sets of ramp angles are available for the differential. Note that a
cross pin of the correct angle is also required. Lower angles give higher locking values. The first value
specifies drive and second value specifies coast. (I.E. 30/45 = 30˚ drive and 45˚ coast). However, the
ramps can be fitted in reverse if requested, e.g. ramp angle of 30/75 fitted in reverse would give 75˚
+drive and 30˚ coast.
Available Ramp Angles

Diff. ramps (α) Diff. ramps (β) Side Gear Ring Cross Pin
30 45 443-449-109B 443-290-009B
30 75 443-449-109C 443-290-009C
45 60 443-449-109D 443-290-009D
45 85 443-449-109A 443-290-009A
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Figure 5. Orientation of ramps 45°/ 85°(shown as example)
3.5.3. Pre-load Setting

A disc spring is used to provide an axial pre-load on the friction pack of the differential. The amount by
which the spring is deflected is controlled by an adjuster plate. This adjuster plate can be adjusted by
Xtrac tooling when the differential is removed from the gearbox. Alternatively, an adjuster wheel,
positioned upwards from the left hand output flange, can be adjusted by an 8mm hex spanner whilst
the gearbox / differential is fully assembled and still installed in the vehicle. A detent plate is used to
provide a positive location in each position. ‘Clicks’ can be felt as the adaptor wheel is rotated and
these can be calibrated to give a measure of how much extra preload has been applied / removed. 6-
9Nm preload per ‘click’ is typical with 8 friction faces per side. Clockwise rotating preload adjuster
increases preload.
Figure 6. Differential preload adjuster Figure 7. Direction to increase preload
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Hyundai i30 N TCR
3.5.4. Pre-load Checking Process

1. Liftring the car from the ground and remove left wheel and lock the left wheel
2. Turn the right wheel and check locking torque
The preload is approximately 85Nm at delivery and with new gearbox. The differential preload
changes significantly before a certain distance is covered with new differential discs. The preload
must always be adjusted when the gearbox is hot condition. The cold measured preload is
approximately 15% higher than warm measure. Differential preload decreases with running mileage,
so please check the preload periodically.
3.5.5. Differential Characteristics

Providing a reference guide to aid differential setups and maps the expected locking performance of
the differential compared to a baseline, where a 30 degree ramp with 16 friction faces is the maximum
achievable locking.
Differential setup and map guide

Ramp Friction Faces Locking Ramp Friction Faces Locking
16 100% 16 13%
30° 12 75% 75° 12 10%
8 50% 8 6%
16 59% 16 0%
45° 12 44% 85° 12 0%
8 29% 8 0%
16 33%
60° 12 25%
8 16%
Figure 8. Differential setup and map guide
This data has been calculated based on a mixture of theoretical and experimental data and is a guide
only, values are not exact.
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Figure 9. Input torque vs Locking torque
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3.6. Clutch
3.6.1. Clutch Specification
Clutch Specification
Type Push type, twin plates
Driven Plate Diameter Ø184 mm (7.25")
Torque Capacity 532 Nm (392 ft.lb)
Release Load 2400 N, new (3300 N, worn)
Assembly Mass (Clutch / Driven plate) 2,75 kg / 0,993 kg
Assembly Inertia (Clutch / Driven plate) 0,0177 Kgm² / 0,0036 kg/m²
Clutch Master Cylinder BREMBO Ø 17,46 mm (Standard)
Figure 10. Clutch assembly
3.6.2. Clutch Maintenance
Driven Plates Maintenance

Driven plate thickness new 2,63mm nominal
Driven plate thickness worn (minimum) 2.22mm
Clutch plate replacement Every 2 spring races
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Hyundai i30 N TCR
3.7. Brakes
3.7.1. Brake Configurations
Brake configurations
Front Rear
Part Name Part Number Part Name Part Number
Brake 58131-TS01 (L)
BREMBO 6 Pistons BREMBO 2 Pistons 58332-TS01
Calipers 58130-TS01 (R)
58113-TS03 (L)
Brake disc BREMBO 380x35mm BREMBO 278x16mm 58312-TS01
58112-TS03 (R)
BREMBO Ø16,00mm 58404-TS01 BREMBO Ø16,00mm 58404-TS01
BREMBO Ø17,64mm
58135-5G01 BREMBO Ø17,64mm 58135-5G01
(Standard)
Master
BREMBO Ø19,00mm
cylinder BREMBO Ø19,00mm 58107-5G01 58107-5G01
(Standard)
BREMBO Ø20,64mm 58108-5G01 BREMBO Ø20,64mm 58108-5G01
BREMBO Ø22,22mm 58404-TS11 BREMBO Ø22,22mm 58404-TS11
PAGID RST1 58137-TS21 PAGID RST3 58142-TS01
Pads PAGID RST3 58137-TS11 PAGID RS44 58142-TS11
Sprint PAGID RST5
58137-TS01 PAGID RSH3 (Standard) 58142-TS21
(Standard)
PAGID RSL1
Pads 58139-TS01 PAGID RSL29
(Standard) 58143-TS01
Endurance (Standard)
PAGID RSL2 58139-TS11
Figure 11. Pedal box with indication of master cylinder location
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3.7.2. Brake Pads Friction Specification
Figure 12. Sprint setup brake pad friction coefficient
Figure 13. Endurance setup brake pad friction coefficient
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3.7.3. Brake Bedding in Process
Brake Bedding in Process

Creating a perfect contact-pattern between rotor and brake pad surface.
10 stops with low pressure and low temperature from 150 km/h (90 MPH) to
st
1 step Breaking-in approximately 80 km/h (50 MPH).
Distance between each brake stop approximately 600 – 800 meters (600 to
800 yards).
Warm up in order to initiate some core heat in the whole brake system.
A sequence of 5 stops with medium to high pressure from 180 km/h (112
nd MPH) to approximately 60 km/h (37 MPH) with maximum acceleration
2 step Heating-up
between the stops.
After the last stop cool down for 3 minutes with the speed preferably not
higher than 100 km/h (62 MPH).
3 to 5 stops with low pressure from 150 km/h (90 MPH) to approximately 80
rd Recovery km/h (50 MPH).
3 step
Stops Distance between each brake stop approximately 600 – 800 meters (600 to
800 yards).
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3.7.4. Rear Brake Pressure Limiter (Proportioning Valve)

Proportioning valves are specially designed for use in competition vehicles where it is desired to
reduce the hydraulic line pressure and therefore braking effort of usually rear brakes to compensate
for varying road/track conditions or vehicle handling characteristics.
This proportioning valve with adjustment handle offers the driver or the co-driver with seven distinct
settings from which to select the most suitable brake ratio. This valve has a nominal ratio of 0,325.
Figure 14. Rear brake pressure limiter lever position
Figure 15. Valves settings chart with tolerances
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3.7.5. Brake balance

Front and rear brake pressure balance is adjustable through the brake balance adjuster on the centre
switch panel. Driver and mechanic check the brake pressure and front rear balance in the “Tires-
Brakes-Gearbox” screen on dash display. The recommended brake balance in dry condition is 55%
front and 45% rear.
Figure 16. Brake balance adjuster Figure 17. Brake pressure check on display
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3.8. Lifting System
3.8.1. Air Jack Specification
Air Jack Specification

Lift Capacity 675 kg
Maximum Operating Pressure 30,0 bar
Bore Size 54,0 mm
Piston Stroke 310,0 mm
Figure 18. Air jack
3.8.2. Air Jack Maintenance

Do not use petrol or paraffin for cleaning the air jack as this will damage the rubber Seals. Use an
alcohol based cleaning fluid i.e. Methylated spirit. For internal lubrication, use only silicone spray or
silicone grease as required.
3.8.3. Air Jack Connector

The air jack connector sleeve is automatically pushed when the air pressure is connected. To lowering
the car, the connector sleeve needs to be pulled out to release the air pressure in the air line. The
connector sleeve has to be pulled out to the end when the car is running.
Figure 19. Air jack connector sleeve position when car running (Left: OK, Right: NG)
Working under the car supported only by the air jack without the safety pops is forbidden.
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3.9. Fuel Tank
3.9.1. Fuel Tank Specification
Fuel Tank Specification

Fuel tank capacity 100 litres
Material Rubber (FIA Standard FT3 bag)
Fuel pump configuration Lift pump (2ea), Main pump (1ea)
Lift pump flow rate 126 litres/hour @ 0.21 bar
Main pump flow rate 140 litres/hour @ 5 bar
Figure 20. Fuel tank layout
3.9.2. Refuelling - Sprint

The fast coupling plug and external fuel pump is required to fill the fuel. The location of the fuel tank
filler and fast coupling plug is illustrated in Figure 21 and Figure 22.
The endurance kit includes external fuel filler for faster refuelling as in the Figure 23.
Figure 21. Fuel tank refuelling filler (Sprint) Figure 22. Fast coupling plug (Sprint setup)
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Figure 23. Fuel tank refuelling filler (Endurance)
3.9.3. Defueling
The defueling hose has to be connected to the defueling connector in the engine bay for defueling.
The fuel is out from the defueling connector when fuel pump is forced activated. You can activate the
fuel pumps with Dash Keyboard, please refer the 5.2 Drivers Display.
Figure 24. Defueling connector Figure 25. Defuel hose connector

(Goodridge GQD05PS06F)
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3.10. Headlights
3.10.1. Headlight Replacement

Please disconnect the battery quick connector.
3 fixations per each side (left and right) have to be removed to replace the headlights and one
connector per side has to be disconnected as below Figure 26 and Figure 27. The endurance headlight
has same fixation and connector.
Figure 26. Headlight fixation Figure 27. Headlight connector
3.10.2. Headlight bulb replacement

Please disconnect the battery quick connector before change the headlight bulb.
When you handle the light bulb, handle them carefully and avoid scratches and abrasions. If the bulbs
are lit, avoid contact with liquids. And never touch the glass with bare hands. Residual oil may cause
the bulb to overheat and burst when lit. A bulb should be operated only when installed in a headlamp.
If a bulb becomes damaged or cracked, replace it immediately and carefully dispose of it.
Remove the bulb cover by turning it counter-clockwise. Disconnect the bulb socket-connector and
remove the bulb from the headlamp assembly. Then install a new bulb. Connect the bulb socket-
connector. Install the bulb cover by turning it clockwise.
Figure 28. Headlight bulb replacement
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3.11. Brake Quick Release Connector
For the faster brake system replacement, you can install the quick realise connector in the flexible
brake line. You need to replace the flexible hose from body side to calipers.
Figure 29. Brake hose with Quick Release connector, front and rear
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3.12. Torque & Loctite Settings
3.12.1. Engine Assembly
Figure 30. Engine mounting bracket
Figure 31. Clutch fixing bolts
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Figure 32. Flywheel fixing bolts
Figure 33. Steering pump bracket
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Figure 34. Anti-torque bracket to subframe
Figure 35. Turbo bracket assembly on engine block
Figure 36. Fuel tank plate bolts
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3.12.2. Gearbox & Drive Train Assembly
Figure 37. Gearbox bolts
Figure 38. Output flange bolts on engine block
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Figure 39. Driveshaft bolts
3.12.3. Chassis Assembly
Figure 40. Front subframe to chassis and anti-torque
Figure 41. Rear subframe to chassis and anti-torque
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Figure 42. Pedal box
3.12.4. Front Suspension Assembly
Figure 43. Front upright accessories and damper to upright
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Figure 44. Front wishbone to subframe
Figure 45. Front anti-roll bar blade to subframe
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3.12.5. Rear Suspension Assembly
Figure 46. Rear upright accessories and damper to upright
Figure 47. Rear trailing arm bolts to chassis
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Figure 48. Rear lower front arm
Figure 49. Rear lower rear arm
Figure 50. Rear upper arm
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Figure 51. Rear damper mount on chassis
Figure 52. Rear anti-roll bar blade to subframe
3.12.6. Steering Assembly
Figure 53. Steering rack to subframe and toe links
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3.12.7. General Tightening Torque
General Tightening Torques

Size Pitch Grade 8,8 Grade 10,9 Grade 12,9
M5 0,8 5,7 8,1 9,7
M6 1,0 9,8 14,0 17,0
M8 1.25 24,0 33,0 40,0
M10 1,5 47,0 65,0 79,0
M12 1,75 81,0 114,0 136,0
M14 2,0 128,0 181,0 217,0
M16 2,0 197,0 277,0 333,0
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3.13. Fluids
Fluids Type Quantity

Engine oil Shell Helix Racing 0W-40 7,0 litres
Gearbox oil 75W90 RHD 1,5 litres
Power Steering oil Shell Spirax S4 ATF HDX 1,4 litres
Brake oil Brembo Racing HTC 64 T
Clutch oil Brembo Racing HTC 64 T
Engine coolant Redline water wetter additive
Fuel Panta 100 litres (Full)
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3.14. Identifications
3.14.1. Chassis number
Figure 54. Vehicle identification number plate on the safety cage
3.14.2. Engine sealing number
Figure 55. Engine head and oil sump sealing Figure 56. Manufacturer seal
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4. CONTROLS
4.1. Switch Panel
Figure 57. Switch panel
Photography Function Remarks
Engine Start When useable light ring is Blue.
Engine Kill When useable light ring is Red
Low beam lights are displayed as green, high

Headlights beam as blue. (To activate high beam use
flash button on steering panel).
Displayed as green for rain light and as yellow

Rain Lights
for when pit limit is active.
Driver Fan Displayed as green when on.
Heated windscreen will only run if the engine

Heated
is running. Displayed as light blue for only
Windscreen and
blower fan and as green for heated
Blower Fan
windscreen and blower.
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4.2. Steering Wheel
4.2.1. Steering Wheel Switch Panel
Figure 58. Steering wheel switch panel and shifting paddle
Label Function Remarks
Press to Talk  Closes PTT output in radio connector
Activate Launch  Hold to activate launch control
 Click the button, yellow flag speed limit is

Active Yellow Flag
activate
Speed limit
 Endurance only
 Pos1 - No control
 Pos2 - Intermittent Wiper
Wiper and washer
 Pos3 - Slow Wiper
control
 Pos4 - Fast Wiper
 Pos5 - Washer activate
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 Pos1 – Dry condition

Engine Calibration  Pos2 – Damp condition
(ABS Calibration for  Pos3 – Wet condition
endurance)  Pos4 – Safety
 Pos5 - Emergency mode (Limp mode)
 Click to Flash
Flash / High Bean  Hold for 1 second to activate high beam
 Flash is available at all times
 Click to activate
Pit Limiter
 Click to deactivate
 Click for 3 flashes

 Hold for 1 second to keep indicator on
Left Indicator  Click to switch off
 Hold both Left / Right indicator for 2 second to
reset the fuel consumption
 Click for 3 flashes
 Hold for 1 second to keep indicator on
Right Indicator  Click to switch off
 Hold both Left / Right indicator for 2 second to
reset the fuel consumption
Clear “Soft” Alarm  Clears soft alarms

Page change  Scrolls through display screens
 Press to activate drink pump

Drink pump  Pump will run for a further 2 seconds after
release
Up shifting  Pull right side paddle to upshifting
Down shifting  Pull left side paddle to downshifting
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5. ELECTRONICS
5.1. Dash Keypad
Figure 59. Dash keypad Figure 60. Dash keypad Connector position
Label Function Remarks
Navigation Left & Right  Navigate between pages
Navigation Up & down  Navigate items on pages
OK  Select items on page
Back  Exit a selected menu
Home  Move to home screen (Warm up screen)
Menu  Bring up menu on display
5.1.1. Drivers Menu

Please hold the right navigation button of dash keypad for more than 2 seconds to access drivers
mode.
Label Function
 Click OK to return to the previous screen
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 Click OK to clear the fastest Lap
 Click OK to get the menu below
 ANY: Not Used

 GPS: The dash will use the GPS signal for a Lap Beacon
 PULSE: The Dash will use a Physical Beacon Pulse
 EVENT: Not Used
 Switch: Not Used
 CAN FRAME: Not Used
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5.2. Drivers Display
Name Display Design Remarks
 In the warm up, driver can check the

Warmup important temperature and pressure
Screen
 Available when car is moving
 When the speed is over 5km/h, the

Race screen is moved to Race Screen
Screen
 Display engine parameters

- Engine coolant temp / pressure
Engine - Engine oil temp / pressure
Parameters - Intake boost / manifold pressure
- Direct injection fuel pressure
- Fuel pressure
 Display tire, brake and gearbox info

Tires - Wheel travel
Brakes - Brake pads temperature
Gearbox - Brake pressure
Screen - Gearbox count
- Xtrac error count
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 Display the analogue setup

- Throttle position
Analog
- Gear shifting air pressure
Setup
- Clutch hydraulic pressure
Screen
- Gearbox oil temperature
- Lambda
 Black output
- Off
 Green output
Powerbox
- On
Status
 Yellow output
Screen
- In inrush phase
 Red output
- Tripped
 Using the keypad for below

instruction
 Fuel pumps
- Click OK once to start pumps, Cick Ok
Mechanics once to stop pumps
Page
 Gearbox Compressor
- Click OK once to force Gearbox
compressor, it will run for 2sec. Forced
is only available under 9 bars pressure
in the accumulator.
 Pedal Learning
- Move calibration knob to 5, Limp.
- Holding the OK button for the duration
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wait for the message to change from

ENABLING to LEARNING. At this point
while still holding the OK button move
the throttle pedal to 100% and back to
0% with similar force from foot. Wait
for the SUCCEEDED message.
- You can release the OK button and
return the calibration knob. Check on
the ANALOG SETUP screen that the
range is correct for the PPS.
 Steering Angle Zero

- Move the steering wheel to the central
position. Click and hold the OK button
for 5 seconds. To test move steering
from left to right.
 Using the keypad for below

instruction
Race  Reset Fuel Consumption

- Click OK button to reset the fuel
Menu
consumption
 Fuel Used Type

- Select either Litres or Kilograms
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 Yellow Flag Speed (Endurance only)

- Select 60kph, 70kph, 120kph or we can
have 2 different speeds based on gear,
1st+2nd 60kph and 3rd+ 120kph
 Pit Limit speed

- Select 50kph, 60kph, 40kph or 56kph
(35mph)
Messages
Screen
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5.3. Launch Start
5.3.1. Launch Start Procedure
Launch Procedure – Start preparation

1 Select the Calibration rotary for the conditions, Dry / Damp / Wet
2 Press and hold the “LAUNCH” button (Display screen moves to Launch automatically)
3 Hold the hand brake at around 90 Bar pressure (Handbrake pressure bar colour change to green)
4 Fully depress the clutch pedal
5 Select 1st gear (Gear position bar colour change to green)
6 Press and hold the throttle pedal fully to 100% (Throttle pedal bar colour change to green)
7 Find the biting point of the clutch, around 13 Bar (Clutch pressure bar colour change to green)
Figure 61. Launch screen Figure 62. Ready to start
Launch Procedure – Start and Releasing

1 To start, release both the handbrake and the clutch simultaneously
2 When the screen background colour change to green (at 65km/h) release the Lunch button
Figure 63. Releasing point of Launch button (vehicle speed 65km/h)
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5.4. Software Installation
Software Installation
Run the “LifeSetup-Generic package” to

install the LifeRacing Software.
Select “Yes”
Choose “Yes” if you would like to check

Demo files to have a look at before
running.
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Choose “Yes” if you would like the

desktop shortcuts
Installation is now complete
We need to first create a Keygen for the

user login you will be using. This is a
remote process done by Hyundai. First
open a piece of LifeRacing software, for
example LifeView (the data analysis
software)
With the software open double click from

the icon tray in the bottom right corner,
“LifeNetServer”
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Within the LifeNetServer, select

“Security”, then select “Identity Security”
Within the Identify Security screen,

highlight the Hyundai TCR / Team field.
Then select “Create Softlock”
Copy the Softlock Request Code using the

“Copy” button. Then send this via email to
your electrical contact at Hyundai
Motorsport – Customer Racing.
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We will send back to you the Keygen

Activation code. You need to copy this to
the clipboard
Within the Identiy Security screen, click

the “Paste” button, then click “OK”
If everything is OK, you will now have

“Yes” next to the “Softlock OK”.
You are now free to work with the
Hyundai i30 TCR LifeRacing System.
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5.5. Connect and down load – Life Data
5.5.1. Introduction
All menu buttons can be reached using keyboard shortcuts. Each option has an underlined letter,
identifying its shortcut key or the shortcut displayed to the left. Dialogue boxes can be navigated with
the arrow keys. The <Spacebar> can be used to select while <Enter> and <Esc> are used as OK and
CANCEL respectively.
5.5.2. Log Screen

The LifeData log screen shows ECU and download information including:
 Date and time of download
 Cfg file read status
 Device info: software levels and programmed dates
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 Data info
 Data save locations
 Error info (optional)
Save the entire log by selecting File, save logged Output. This will store a text file in the main working
directory. Clear the log screen with Options, Clear log.
5.5.3. Log Screen

The working directory is maintained across all Life Racing applications and can be edited in LifeCal,
LifeCfg, LifeData, LifeView and PduSetup. To change the current working directory select Working
directory under File. Use CREATE to create a new folder in the current location. Use SELECT to select
the current location as the new working directory. If the location has not been used before, a .CFG file
will be created. Selecting Working Dir Behaviour allows editing of the .CFG file.
Devices that have been previously connected to are automatically added to the known devices list.
They can also be manually added or imported from another working directory with the appropriate
buttons. The ECU name will be used as a folder name if device directory is used. The suffix is included
in file names.
Directories can be altered individually for calibrations, downloaded data and logging setup files. Tick
use directory per device to separate files by ECU. Tick Use directory per session to use either the Date
sub directory or a custom sub directory. A Date sub directory will automatically update and add
folders when new data is downloaded.
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5.5.4. Autoread
AutoRead is designed to minimize the amount of time a connection is required. Selecting Device,
AutoRead will bring up the same dialogue as an ordinary read but without a connection being
required. The settings can then be set before a device is connected. Once AutoRead is active, LifeData
will begin searching for a device. As soon as one is connected, the data will be downloaded to the
working directory and any additional operations completed.
Additional AutoRead options can be found under Options, AutoRead.
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Enable Ignore Sessions Already Acquired to not download any files with matching names in the
working directory. This also effects normal reading.
Enable Delete sessions after download to automatically delete downloaded files from the ECU
memory. A normal read will ask after every download.
Enable Get Error Info to display errors in the log display. Useful for finding sensor failures. This also
effects normal reading.
Enable High Visibility for full screen status display when AutoRead is active.
Sweeping bar  searching
Expanding/Contracting Bar  decoding/downloading
Flashing screen  complete
Enable Restrict auto-downloads to named devices to only automatically download from the devices
listed. Any other device will be ignored and require a manual read.
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5.5.5. Read
To download data from a connected device select Device, Read data. LifeData will then search for and
connect to a device, and give download options.
For efficient management LifeData only downloads files that do not exist in the working directory by
default. However, if a different working directory is used, LifeData will read the entire contents of the
ECU (this may take some time). To avoid this situation, a date limit can be applied to ignore any old
data.
Selecting QuickView will allow you to view the most recent data as quick as possible. Specify a
download time (real time not data time i.e. 5 seconds of downloading is probably the last few laps of
actual track running) and once this time expires the data is automatically opened in LifeView and
presented using your default worksheet for quick analysis while the software continues to download
the full data in the background. These quick view files are stored in a sub directory called “QV”. Any
interruption to the download process is automatically stored in a sub directory called “PARTIAL” which
can also be open and viewed.
Enable suffix to add a run number suffix to file name. Set the Run Number to select the initial number
used. The number is then automatically updated for each download.
Enable Calibration-Programming to programme a calibration to the ECU immediately after download.
This saves time by allowing the two operations to happen with a single command.
The files will be downloaded to the working directory and the log screen will be updated.
5.5.6. Stream
If an ECU is staying connected to a PC, the logging can utilise the PC’s internal memory by streaming
data. This will allow much larger files to be created than with the ECU memory. To begin streaming,
select Device, read Streamed data.
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5.5.7. Comments
LRD files can have comments added before download or during the read process. Pre-set the
comments before reading with Device, set LRD file Comment. This will be remembered for all
subsequent downloads until edited or the programme is closed.
Logbook files cannot be edited during or after a download. The logbook comment must be set whilst it
remains in the ECU. To do this, select Device, Logbook Comment. The user and root comments are
separated and may display differently if at all depending on security settings.
5.5.8. Decode .LRS

LRS files from USB datalogging must be decoded into .LRDs before they are viewable. To do this,
select File, decode Streamed data and locate the .LRS file. Alternatively, decode an entire folder with
decode Streamed data folder. The new files will be located in the working directory.
5.5.9. Quick View

Downloaded files must be viewed in LifeView, however LifeData gives the option of loading these
directly from its file menu. Select File, Load in LifeView to select a file or files that will then be opened
in LifeView. The latest file can be opened without having to locate it with Load latest Data in LifeView.
5.5.10. Global Option

Global options affect all applications and can be found under File, Global Options.
 Black-on-White colour scheme

Toggle the colour scheme of all Life Racing applications between a white background and a black
background. The best option will be dependent on screen quality, ambient lighting and user
preference.
 Colour Blind (yellow/green)

Changes fixed yellows to purple to aid with yellow/green confusion.
 Reverse Folder Order (in file menu)

Folders are ordered alphabetically in the file menu. Tick this box to reverse this order.
 Floating Mouse Focus (in dialogs)

Causes whatever the mouse pointer is hovering over to be highlighted as if it was selected with the
keyboard.
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5.6. Open and Read Data - LifeView
5.6.1. Instruction
LifeView is a data viewing application. Downloaded .LRD files can be analysed here with the use of
intelligent visual representation.
Due to continuous development, some features may change and this manual will update periodically.
Please ensure you have the latest version dated on the cover page of this document.
 Information Panel
The Information Panel is displayed at the bottom of the screen and can be toggled with the <F1> key.
It displays:
File location, name, time stamp and size Highlighted channel Highlighted channel
ECU serial number, Calibration and code levels name, frequency, unit and burst logging state
No of laps and fastest lap unit group
Saved comments
 Menu Shortcuts
Life Racing applications are intended for quick operation without the use of a mouse for improved
usability in the pit lane. All menu buttons can therefore be reached using keyboard shortcuts. Each
option has an underlined letter, identifying its shortcut key or the shortcut displayed to the left.
Dialogue boxes can be navigated with the arrow keys. The <Spacebar> can be used to select while
<Enter> and <Esc> are used as OK and CANCEL respectively.
5.6.2. Files – Load / Import
 .LRD
To load data, select File, Load and locate the chosen file. File name and size is displayed as well as a
time bar that shows the timing in comparison to other files in the same folder. Time bars will alternate
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in colour for different sessions determined by the time difference between them. Highlight a file to
display further details including device details, lap details and any comments.
Multiple files can be opened at once and stitched together (concatenated) in the software with or
without time gaps. This is done using the <Shift> key to select consecutive files. A dashed line in the
graphical display indicates the beginning of a new data set.
Select File, Load anOther to overlay multiple files on the same display to allow comparisons. Overlaid
files can also be concatenated.
 .CSV
LifeView can be used to view data from other sources by importing a comma separated .csv file. This
can be useful in instances such as comparing real data to imported simulation.
This is done under File, Import CSV. Select the file and define the ‘time’ field as well as all fields that
are to be imported. Imported files must have a time field to use as an x-axis reference. Files are
imported alongside currently open files to allow overlays.
There is some limited functionality as special channels cannot be configured outside of an LRD file.
Channels can however still make full use of math functions and graphical representation.
 .LB
LifeView can also be used to view and export .LB logbook files. To view these select File, Load logbook
and select the folder location. This will load all .LB files in the selected folder. These can be viewed as
an overall record or as a per run entry.
The Comment option is unavailable in LifeView as logbook comments cannot be edited once the .LB
has been downloaded. Comments can only be added to a logbook whilst it remains in an ECU. This
can only be done when connected in LifeCal or LifeData.
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Select Export to save a text file containing the currently displayed information, whether it is the overall
record or an individual run.
Select exportAll for a text file including all runs and the overall record.
Select Run Sheet for a tab delaminated text file containing every run. This is the easiest exportation for
loading in another program.
Selecting change Units will change the units of the entire unit group. Note that this change will also
affect normal LifeView channels.
5.6.3. Files – Save / Export
 Save
Saving a file will allow concatenated files to be permanently saved as a single file and any annotations
or comments stored. To save, select File, Save, then CREATE for a new folder in the current location or
SELECT to confirm the current folder as the desired location and then enter a new filename.
Select Rename to overwrite the current file with a new name. Default filename contains date and time
at engine start, plus time to beginning of logging, ECU serial number and working directory stamp.
Select save as Logging conFig to retrieve an .LRL file with the original logging configuration. This is
useful when the original file is lost or unavailable.
 Export
Exporting a file will only export the selected channels in the visible time frame. Use zoom to Selection
to select this time frame. Select File, export To, to export data as a text file (.txt or .csv) or as an LRD
file under the same security as the original file or as an unprotected generic file.
 Print
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Select File Print to print the current display including cursor location and values.
5.6.4. Graph
The graph is the primary display tool. It plots selected channels across the duration of the session by
either distance or time (Toggled in the Options menu).
A cursor is used to navigate the data. Above the graph, numerical values at the current cursor location
are given for time, distance and the selected channel. Placing a marker will also give delta values
between the marker and cursor locations.
Optional visual aids include a crosshair at the highlighted channel data point, an average value or the
minimum and maximum values for the visible data and more. These can be toggled in the Options
menu.
Annotations will appear as dashed vertical lines at the selected sample location. Hover the mouse over
these to display the text.
5.6.5. Navigation
The graphical area is designed to allow quick and easy navigation of potentially large amounts of data.
Both the keyboard and mouse can be used individually or together to achieve this.
Left Click Place cursor

Mouse
Right Click Place marker
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Left Drag Move cursor

Right Drag Zoom to selection
Scroll Zoom X-axis
Ctrl Scroll Zoom Y-axis
Double Click Add/edit annotation
Drag Y-Axis Move axis maximum
Ctrl Drag Y-Axis Move axis minimum
Shift Drag Y-Axis Move entire axis
<Left> Move accelerating cursor to left
<Right> Move accelerating cursor to right
[ Move cursor left to previous different value
] Move cursor right to next different value
< Move cursor to previous alarm position
> Move cursor to next alarm position
<F6> Move cursor to minimum visible value
<F7> Move cursor to maximum visible value
<Ctrl> + <Left> Move cursor to left by 10% of screen
Keyboard <Ctrl> + <Right> Move cursor to right by 10% of screen
<Shift> + <Left> Accelerating scroll to left
<Shift> + <Right> Accelerating scroll to right
<Plus> Zoom in X-axis
<Minus> Zoom out X-axis
<Ctrl> + <Plus> Zoom in Y-axis
<Ctrl> + <Minus> Zoom out Y-axis
<Tab> Toggle graph focus when multiple graphs are open
<Space> Place marker
<Backspace> Remove marker
The Zoom menu can also be utilised with its shortcuts to Zoom To Selection, Zoom Previous or Zoom
Right Out.
Certain options such as cursor acceleration and right click zooming can be toggled, depending on user
preference when navigating.
5.6.6. Channels
Channels include all monitoring items and added math functions. These are displayed in the ‘Key’, to
the right of the graphical display. The Key has two modes of operation, selectable in the options menu.
The normal mode shows all the channels in a data file. It gives the value of each channel at the current
cursor position. Channels that are shown in one of the graphs also have a colour tab to show their
respective trace colours. The alternative mode only shows those channels displayed in the graphical
display area. If more than one graph is displayed, there will be separated lists for each. The
information panel will display which file the highlighted channel is from.
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Key navigation uses a different set of shortcuts to graph navigation, allowing simultaneous use.
<Up> Up one channel

<Down> Down one channel
<Page Up> Up page of channels
<Page Down> Down page of channels
<Return> Add/Remove channel on focus graph
<Right Shift> Toggle between data files when more than one loaded
<Delete> Remove math channel
The Channel menu displays the same options as right clicking a channel in the key:
Add
Add a channel to the active graph. Select from the list or begin typing the name of the desired channel
to shorten the list.
Remove
Remove the highlighted channel from the active graph.
Colour
Change the colour of the channels data trace. Tick remember to use the selected colour as default for
all files.
Scale
Auto scale sets the minimum and maximum scale values to the minimum and maximum found in the
data.
Set scale allows custom minimum and maximum values. Tick the remember box to set the new scale
as default. Remember current scale can also be used.
The Scale can also be edited by right clicking the y-axis in the graph area.
Filter
Add a new trace containing the filtered values of the highlighted channel. This will not be available for
channels logged at 1Hz.
AlarMs
Set thresholds for the selected channel. Thresholds will be displayed as dashed lines at the set values.
When these values are exceeded, the channel will flash in the key. Alarms are only monitored in the
visible time frame.
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Sample Average Limits

Set the upper and lower limits of values to be used in Averaged Samples Mode calculations.
Change Units
Change the display unit of all items in unit group. If a single unit change is desired, a math channel can
be used to achieve this. Note that units are universal across files and applications.
Edit Math
Open the math window for the selected math item.
Delete Math
Remove the math channel from the display and key.
5.6.7. Math
Math can provide a wide range of further data manipulation varying from simple scaling to complex,
multi-function expressions. Choose a new or existing maths expression from the Math menu to open
the Math Window. The Math window enables the adding and editing of math channels. Once added,
the math channels behave the same as data channels with the additional right click options of editing
and removing. Delete a maths expression by highlighting it and pressing the <Delete> key on the
keyboard.
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Name
Create a channel name for your maths channel. Must not contain these characters:
Full Stop . Less than <

Forward Slash / More than >
Back Slash \ Vertical bar |
Colon : Quotation marks “
Expression
Type your maths expression here. Expressions can include any monitoring item or other maths
channel. Take care when adding channels as they are case sensitive. Suggested functions or variables
will be displayed as you type. Use the <Enter> key to select the highlighted suggestion. When a
function is selected, it will automatically be highlighted in the functions list below so the format it
expects is visible. Error hints will appear when the expression is invalid. Right click this box to cut,
copy or paste.
Functions
This list contains all functions available in alphabetical order. Highlighting a function will display an
explanation. Double clicking or using the <Space> bar will paste the function into your expression.
The full list of functions and details on how they are used can be found in the Math Manual, available
for download from www.liferacing.com under Support, User Manuals/Datasheets.
Units
Select the unit group and unit that the result will be outputted in. This will display on the y axis label.
Auto Scaling
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Tick box to enable auto scaling or type custom min max values for y axis. Auto scale will use the max
and min values of results as the scale max and min.
Dec Places
Type the number of decimal places to be displayed in results. This is a visual option only and does not
affect calculation accuracy.
Auto Sample Rate

Tick box for automatic sample rate. This will use the highest sample rate of the items used in the
expression. It will also follow burst logging rates. For custom sample rate, type in the box how many
times a sample should be taken in a second.
User Sample Offset

Maths channels can create delays when referencing multiple points. Sample offset allows the shifting
of data by the typed number of samples. Number of samples must be less than sample rate.
5.6.8. Lap Mode

Lap mode causes the program to treat the selected lap as an entire file and will temporarily display
only the selected lap. Select any lap from the Lap menu to enter lap mode. From the same menu, any
other lap can be displayed or lap mode switched off. This is most useful when multiple files are open.
If properly overlaid, a lap can be selected from one dataset while the other does not change, allowing
easy lap comparisons.
5.6.9. Multiple Files

The load anOther option in the File menu allows multiple sets of data to be compared on the same
display. The key will display each data set in separate columns with a differing colour assigned to all of
its items by default (Can be switched off in Options). Hold the left <Shift> key and drag on the
graphical display to offset an added file. Return any additional open files to their original positions by
selecting Session, Reset Offsets. Multiple files are easier to compare in distance mode rather than time
to account for the differing lap times.
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5.6.10. Worksheet
A worksheet is a saved layout design including graphs, track maps, reports and active channels. These
can then be used with any future set of data. Worksheets are saved and opened in the Worksheet
menu. Save a new worksheet with Save and type a name, or an existing worksheet with Overwrite.
Worksheets can be renamed with Rename worksheet and deleted with the <Delete> key. The
worksheet set as default will be automatically used when a file is opened and is marked with an
asterisk (*). Others can be selected in the same menu with its numerical shortcut.
5.6.11. Workbooks
Workbooks allow worksheets to be grouped together. By default, a single workbook named “default”
is created. To create a new workbook, set a new default, rename or delete an existing workbook use
the corresponding menu options in the same way as worksheets. Workbooks are saved automatically.
Worksheets can be copied from one workbook to another with Add worksheet to workbook.
A workbook will display all of the worksheets contained as tabs. These can be toggled with
enable/disable Tabbed worksheet. This allows quick transition between pages by selecting the relevant
tab.
Workbooks can be imported and exported to allow the transfer of worksheets to other computers.
Select Worksheet, Export Workbook to create a file in a chosen destination. This file can then be
transferred and imported by another user with Import Workbook.
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5.6.12. Graphs
Additional graphs can be added to worksheets under the Graph menu. Multiple graphs are displayed
vertically so they can share the same x-axis. Graphs can be resized but as they share an x-axis will
remain equal width. Selecting Graph, Tile will evenly distribute allocated height. The active graph and
channel in the active key (alternative key style) will be highlighted and can be switched between with
the <TAB> key.
5.6.13. Reports
Reports are added from the Report menu. A separate window will be opened where the report can be
edited. From here, reports can be printed, exported or docked in the worksheet.
Reports will only display information form the currently visible data so ensure the graph is zoomed to
the data range desired.
Lap Report
This report can only be used by a single file. With multiple files loaded, only the first file [0] is used. Lap
reports display max min and average values for either displayed channels or all channels across each
lap. Select Dump to save a text file.
XY Plot
An XY plot allows any channel to be assigned to either axis to produce a scatter graph. Selecting
Report, XY Plot will open a new window with a blank plot.
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Assign each axis with the relevant button. The XY axes can be swapped under Options, Swap XY.
Colours appear darker where data is more concentrated. Numerical values can be seen for each axis in
the bottom left hand corner.
A second Y-axis or a Z-axis can also be added. The second Y-axis will use the same scale as the first
but be displayed in a different colour. A Z-axis utilizes colour banding to display different values.
The same channels from different files can be overlaid under Options, Toggle Overlay Mode. Each file
will display in a different colour. Select Reverse Overlay Order to change which file is viewed on top.
Overlay mode only works for a single Y-axis and no Z-axis.
The plot can be resized by either zooming or moving the scales in the same way as the main graph.
Right click the scales for more precise control. When data is highly magnified or when there are fewer
data points it is recommended that intensity is increased for easier viewing under Options, Intensity.
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Colour can also be changed to greyscale with the Toggle Colour/Grey option. This cannot be toggled
when overlay or multiple Y-axes are being used.
Save an XY plot layout as a favourite to quickly reload them when required.
Select Print to print report, Dock to add report to the worksheet and OK to close.
Histogram
A histogram shows the percentage of time an item is within certain value ranges. Added items will be
displayed in the colour set in the Key. Item ranges and the number of ranges can be altered with the
appropriate buttons. Select Print to print report, Dock to add report to the worksheet and OK to close.
Once docked, the active range at the cursor location will be highlighted.
2D Histogram
A 2D Histogram shows percentages like the normal histogram but measures two parameters. Each
parameter can have its ranges individually altered by selecting that item. Save commonly used items
and ranges as favourites to quickly reload them when required. Colours are graded for easier
visualization. Select Copy to place the table values in the clipboard. This can then be pasted into
another application such as Microsoft Excel. Select Dock to add to worksheet or OK to close. When
docked, the value at the current cursor position is highlighted.
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Sector Report
This report can only be used by a single file. With multiple files loaded, only the first file [0] is used.
A Sector Report displays sector times throughout the session with the fastest sector and lap times
displayed in green. The Optimum Lap Time displayed is the potential fastest lap using the total time of
all the quickest sectors. When docked, the sector at the current cursor position is highlighted. The
report can also be used to navigate through the session. Select a sector on the report to display just
that sector on the main graph. Multiple consecutive sectors can also be selected.
5.6.14. Track Map

A track map can be displayed to show the vehicle position throughout the data. The vehicle icon will
follow the map as the cursor is moved on the graph. Alternatively, the same icon can be dragged
around the map and the cursor will follow. The icon will change its appearance when the vehicle is off
track such as in the pits.
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To add a track map to the worksheet, it can either be loaded or created under the TrackMap menu.
Track maps can be created from GPS coordinates or calculated from distance and lateralG. Using the
latter method will require some fine tuning of the various options. All recorded GPS positions will be
displayed with the chosen lap emphasised. Calculated position will display the chosen lap only. By
default, the fastest lap is used.
< GPS (Latitude/Longitude) > < Distance/Lateral G >
Right click on the screen to bring up beacon options. This allows additional beacons to be added for
sector times or the adding of an END beacon for sprint routes.
Once a track has been loaded it can be added to any other worksheet quickly using Add instead of
load. Close the map by either selecting remove after right clicking or Close in the menu.
Select Save to dock and store the created map. Saved track maps can be found in the main Life Racing
folder. Select OK to dock without saving. Once docked, right click the map area to access display
options or use the TrackMap menu.
Dynamic Remap (1)

Redraw the map for each lap, using the new data. GPS only.
Change Datum
Select the lap that time slip uses as its reference lap. Fastest lap is used by default.
Colour by TimeSlip
Colour by time slip from datum lap.
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Colour by Item Value

Colour the map by any other item value.
TimeSlip Emphasis
Change the colour shift emphasis on the amount of time slip.
Rotate
Use the scroll bar or type an angle in degrees to rotate the map.
Print
Print an image of the track map as currently displayed, including car locations and applied colours.
TimeSlip Sync
With this box ticked, the TimeSlip item channel will be synchronised with the map time slip. When
unchecked, a new datum for the map must be chosen as the channel and the map datum will now be
independent. Channel datum can be changed in the Channel menu.
5.6.15. Floating Windows

Track maps and all dockable reports can be made ‘floating’ which will allow them to be moved around
the screen. When overlaying the LifeView window these windows will be partially transparent to allow
the viewing of data beneath. This will change to fully opaque when outside the main window,
including on secondary screens.
Floating windows can be interacted with in the normal way unless the ‘click through’ option is
enabled. This is accessible through the right click menu and will cause all mouse actions to be applied
through to the main window underneath. The menu can still be accessed through the top ribbon.
Floating window positions are remembered within saved worksheets. If a position is no longer
available they will return to the default position.
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5.6.16. Session
The Session menu contains options for the current open files.
Open Windows Explorer

Open file location in windows explorer.
Comment
Edit the Logfile comment.
Reset Offsets
Return any offsets of overlaid files.
GPS Preferences
Alter GPS offset time and filter rate for either the open file only or as defaults for all files.
Special Channels
Choose what monitoring items will be used as special channels. It is these channels that are used to
calculate vehicle position. Tick Remember to set as defaults.
Beacons
Select where to take beacon information from; the track map or data. When a track is created, it stores
the beacon position from the data plus any beacon alterations done. It is these that are used by
default.
File beacons can also be edited. They can be added, moved or removed completely with the
appropriate menu options. Alternatively, select make beacons persistent to overwrite the file beacons
with the map beacons.
copy Info to clipboard

Copy specific file information so that it can be pasted in another programme. If more than one file is
open, the active file (shown in the information panel) is used.
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5.6.17. Toggle Option

Toggle options are found under Options, All Toggle Options.
Time of day on X-axis

Display time of day or time into session.
Distance Mode
Toggle the X-axis between time and distance. Distance is often more useful when comparing multiple
data sets.
Interpolate Mode
Toggle between displaying raw or interpolated data. Interpolation fills the space between data points
with estimated values, creating a smoother look, particularly for low logging rates. However, as these
values are estimated, they may not be an accurate representation.
Minimum Key Style Mode

Toggle between displaying all channels and displaying only active channels.
Show Item Names

Show active items in the top left corner of the graph display in their line colours.
All Min Max Mode

Toggle whether to show just the select channel max and min values or all active channels.
Bright Key
With bright key deactivated, any unused channels on display in the key will be dimmed.
Bold Focus Trace

The selected channel is always brought to the front of the display. This toggle will also cause the
selected channel to have a bolder trace than the others for clearer viewing.
Shared channel colour per session

With this selected, whenever additional files are overlaid, each file will be assigned a single colour to
all of its
Average on Focus
Show the average of the selected channel in the visible period.
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Averaged Samples Mode

Average samples mode will display only the average value for each channel in the visible area.
The most commonly used toggles are also available directly under the Options menu to allow quick
key presses.
Time/Distance Toggle
Interpolate Toggle
Key Style Toggle
5.6.18. Cursor Options

Cursor options are found under Options, Cursor Options.
Enable Cursor Acceleration

Continuously speed up cursor movement the longer an arrow key is held.
Limit Cursor Acceleration

Limit the cursor to a finite speed chosen with the scroll bar.
Channel Info Tooltip

Display channel name and value at the point the mouse cursor is hovering over.
Right Mouse Zooming

Allow or disable selection zooming by dragging with the right mouse button.
Cursor Crosshair
Toggle the horizontal crosshair. This line will follow the value of the selected channel at the cursor
time position.
Manual Cursor Crosshair

Crosshair follows mouse pointer rather than data values.
5.6.19. Concatenated File Options

Concatenated file options can be found under Options, Concatenated File Options.
Enable default concatenation actions

Enable to skip dialogue options during concatenation.
Preserve time gaps

Keep gaps between log files automatically.
Collapse time gaps

Eliminates gaps between log files automatically.
5.6.20. Global Options

Global options affect all applications and can be found under File, Global Options.
Black-on-White colour scheme
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Toggle the colour scheme of all Life Racing applications between a white background and a black
background. The best option will be dependent on screen quality, ambient lighting and user
preference.
Colour Blind (yellow/green)

Changes fixed yellows to purple to aid with yellow/green confusion.
Reverse Folder Order (in file menu)

Folders are ordered alphabetically in the file menu. Tick this box to reverse this order.
Floating Mouse Focus (in dialogs)

Causes whatever the mouse pointer is hovering over to be highlighted as if it was selected with the
keyboard.
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5.7. Logging channel List
Engine
Logging Name Description Unit / Possible Value
aat Ambient Air Temperature ℃
act1 Air Charge Temperature ℃
alsCal ALS Calibration
alsSelect ALS Calibration
alsState ALS Running State
bap Barometric Air Pressure mBar
btMax ECU Temperature ℃
dbw1Err Drive By Wire Positional Error %
dbw1Targ Drive By Wire Positional Target %
dip1 Direct Injection Pressure Bar
dip1Err Direct Injection Pressure Error Bar
ecp Engine Coolant Pressure mBar
ect1 Engine Coolant Temperature ℃
egt1 Exhaust Gas Temperature ℃
eop1 Engine Oil Pressure mBar
eot Engine Oil Temperature ℃
fp1 Fuel Pressure Low mBar
fuelConsVol Fuel Used litres
fuelPump1 Low Pressure Fuel Pumps Switch ON/OFF
fuelPump2 High Pressure Fuel Pump Switch ON/OFF
ipp1 Air Charge Pressure mBar
lam1 Lambda Value %
launchSelectSwitch Launch Mode Select DRY/DAMP/WET
launchState Launch State
launchSwitch Launch Button State ON/OFF
limpMode Limp Mode Active OFF/FACTORS
map1 Manifold Air Pressure mBar
ppsA Pedal Position Sensor Track A %
ppsAV Pedal Position Sensor Track A Voltage Volts
ppsB Pedal Position Sensor Track B %
ppsBV Pedal Position Sensor Track B Voltage Volts
revCutActive RPM Cut Active IDLE/ACTIVE
revLimitActive RPM Limit Active IDLE/ACTIVE
rpm Engine RPM rpm
runMode Engine Run Mode
sdip1Duty PWM Duty High Pressure Fuel Pump %
syncState Engine Sync State OFF/TURN/360/720
tps1 Throttle Position Sensor Calculated %
tps1A Throttle Position Sensor Track A %
tps1B Throttle Position Sensor Track B %
trqFuelSev Torque Fuel %
vvt1Ex Varible Valve Timing Exhaust Position °
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vvt1In Varible Valve Timing Intake Position °

vvtExTarg Varible Valve Timing Exhaust Position Target °
vvtInTarg Varible Valve Timing Intake Position Target °
wgBaseDuty1 Wastegate Base PWM Duty %
wgFinalDuty1 Wastegate Final PWM Duty %
wgIntDuty1 %
wgMapTarg1 Manifold Air Pressure Target mBar
GPS
gpsAccTemp GPS Accelerometer Temperature ℃
gpsAltitude GPS Altitude mBar
gpsCourse GPS Direction Compass °
gpsFixQual GPS Quality
gpsGyroTemp GPS Gyro Temperature ℃
gpsHrzDil
gpsLat GPS Lateral Co-ordinate Angle, Minutes
gpsLong GPS Longitudinal Co-ordinate Angle, Minutes
gpsMode GPS Mode (Based on Quality)
gpsNumSats Number Of GPS Satalites Seen
gpsSatInfo
gpsSpeed GPS Speed km/hour
gpsStatus GPS Status
Gearbox
gearV Gearbox Barrel Sensor Voltage Volts
changeLightStage Shift Light Stage 1 / 2 /3 / 4 / 5
clutchSwitch Clutch Switch On at 10 Bar
gbt_U15 Gearbox Oil Temperature ℃
st nd rd th th th
gear Gear Selected REV/1 /2 /3 /4 /5 /6
gearBlipState Engine Blip For Downshift
gearCutState Engine Cut For Upshift
gearDownshiftOutput Output to Gearbox To Initiate Gear Shift ON/OFF
gearShiftDecision Reason Of Missed Gear Shift OK/NG FACTORS
gearShiftDirection Direction Of Last Gear Shift UP/DOWN
gearUpshiftOutput Output to Gearbox To Initiate Gear Shift ON/OFF
gsp Gearbox Air Accumulator Pressure mBar
gspControl Gearbox Air Compressor Switch ON/OFF/RELIEF/LEAK
paddleSwitch Input from Paddle Shift NONE/DOWN/UP/BOTH
xtCtrDnshift Xtrac Downshift Counter
xtCtrUpshift Xtrac Upshift Counter
xtError Xtrac Error Code
xtIActuator Xtrac Actuator Current Amps
xtTActuator Xtrac Actuator Temperature ℃
xtTActuatorMax Xtrac Actuator Max Temperature ℃
xtUGear1 Xtrac Gear Volts
Chassis
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flDamper Front Left Damper Position mm
flSpeed Front Left Wheel Speed km/hour
frDamper Front Right Damper Position mm
frSpeed Front Right Wheel Speed km/hour
rlDamper Rear Left Damper Position mm
rlSpeed Rear Left Wheel Speed km/hour
rrDamper Rear Right Damper Position mm
rrSpeed Rear Right Wheel Speed km/hour
bpf Brake Pressure Front Bar
bpr Brake Pressure Rear Bar
calSelect Engine Calibration Selected DRY/DUMP/WET/SAFE/LIMP
cllTarg1 Combustion Ratio
clpr Clutch Pressure Bar
distance_LV Trip Distance KM km
drivenSpeed Front Axle Average Speed km/hour
fan1_Water_Fan Water Fan Command OFF/ON/RUN/DISABLED
fan2_ECU_Fan ECU Fan Command OFF/ON/RUN/DISABLED
fan6Duty_Start_En Starter Motor Command %
lapCount Lap Counter
lapDistance Lap Distance KM m
lapTime Current Lap Time to selected point Time
lastLapTime Last Total Lap Time seconds
latG Lateral G Force (From GPS) g
longG Longitudinal G Force (From GPS) g
logMarkerSwitch Marker (from pressing Launch button) ON/OFF
pitLimitActive Pit Limit Mode IDLE/ACT/ACT_OUT/ACT_IN
pitSwitch Pit Limit Activated OFF/ON
runTime Current Engine Run Time Time
swa Steering Wheel Angle °
TimeSlip(-1) Time Slip From Fastest Lap seconds
vehicleSpeed Speed Of Fastest Rear Wheel km/hour
wheelSpin Wheel Spin %
yaw Yaw (From GPS) °/sec
PowerBox
Logging Name Description Unit
vbat Voltage Battery At ECU Volts
pduA_VBAT Voltage Battery At Powerbox Volts
pduA_PCBT Powerbox Temperature ℃
pduA_HSATOT Total Current from Powerbox Amps
pduA_HS01_VVT_IN_Adv Output 01 State
pduA_HS01A_VVT_IN_Adv Output 01 Current Amps
pduA_HS02_VVT_IN_Ret Output 02 State
pduA_HS02A_VVT_IN_Ret Output 02 Current Amps
pduA_HS03_Coolant_Fan Output 03 State
pduA_HS03A_Coolant_Fan Output 03 Current Amps
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pduA_HS04_Alternator_CTRL Output 04 State

pduA_HS04A_Alternator_CTRL Output 04 Current Amps
pduA_HS05_Window_Motors Output 05 State
pduA_HS05A_Window_Motors Output 05 Current Amps
pduA_HS06_Blower_Fan Output 06 State
pduA_HS06A_Blower_Fan Output 06 Current Amps
pduA_HS07_GBX_Compressor Output 07 State
pduA_HS07A_GBX_Compressor Output 07 Current Amps
pduA_HS08_GBX_Compressor Output 08 State
pduA_HS08A_GBX_Compressor Output 08 Current Amps
pduA_HS09_Wiper_Fast Output 09 State
pduA_HS09A_Wiper_Fast Output 09 Current Amps
pduA_HS10_Engine_Power Output 10 State
pduA_HS10A_Engine_Power Output 10 Current Amps
pduA_HS11_ECU_Power Output 11 State
pduA_HS11A_ECU_Power Output 11 Current Amps
pduA_HS12_Wiper_Slow Output 12 State
pduA_HS12A_Wiper_Slow Output 12 Current Amps
pduA_HS13_Turn_Left Output 13 State
pduA_HS13A_Turn_Left Output 13 Current Amps
pduA_HS14_Turn_Right Output 14 State
pduA_HS14A_Turn_Right Output 14 Current Amps
pduA_HS15_Heated_Screen_LH Output 15 State
pduA_HS15A_Heated_Screen_LH Output 15 Current Amps
pduA_HS16_Low_Beams Output 16 State
pduA_HS16A_Low_Beams Output 16 Current Amps
pduA_HS17_High_Beams Output 17 State
pduA_HS17A_High_Beams Output 17 Current Amps
pduA_HS18_Ext_Electronics Output 18 State
pduA_HS18A_Ext_Electronics Output 18 Current Amps
pduA_HS19_Lift_Pump_Front Output 19 State
pduA_HS19A_Lift_Pump_Front Output 19 Current Amps
pduA_HS20_Lift_Pump_Rear Output 20 State
pduA_HS20A_Lift_Pump_Rear Output 20 Current Amps
pduA_HS21_Heated_Screen_RH Output 21 State
pduA_HS21A_Heated_Screen_RH Output 21 Current Amps
pduA_HS22_Main_Fuel_Pump Output 22 State
pduA_HS22A_Main_Fuel_Pump Output 22 Current Amps
pduA_HS23_Emergency_Fuel_P Output 23 State
pduA_HS23A_Emergency_Fuel_P Output 23 Current Amps
pduA_HS24_Starter_Relay Output 24 State
pduA_HS24A_Starter_Relay Output 24 Current Amps
pduA_HS25_Brake_Lights Output 25 State
pduA_HS25A_Brake_Lights Output 25 Current Amps
pduA_HS26_Extra_Lights Output 26 State
pduA_HS26A_Extra_Lights Output 26 Current Amps
Edition: 6

Hyundai i30 N TCR
pduA_HS27_Rain_Lights Output 27 State

pduA_HS27A_Rain_Lights Output 27 Current Amps
pduA_HS28_ABS_PowerSteer Output 28 State
pduA_HS28A_ABS_PowerSteer Output 28 Current Amps
pduA_HS29_Internal_12V Output 29 State
pduA_HS29A_Internal_12V Output 29 Current Amps
pduA_HS30_ECU_Fan Output 30 State
pduA_HS30A_ECU_Fan Output 30 Current Amps
pduA_HS31_Driver_Fan Output 31 State
pduA_HS31A_Driver_Fan Output 31 Current Amps
pduA_HS32_Drink_Pump Output 32 State
pduA_HS32A_Drink_Pump Output 32 Current Amps
pduA_HS33_Washer_Pump Output 33 State
pduA_HS33A_Washer_Pump Output 33 Current Amps
pduA_HS34_Spare_Power Output 34 State
pduA_HS34A_Spare_Power Output 34 Current Amps
Edition: 6

Hyundai i30 N TCR
5.8. Trip levels in limp mode
Limp Mode Description and Throttle Body Limit

Throttle
Limp Mode Description
Limit
ACT TRIP More than 80°C for longer than 2,5 seconds 25%
ECP TRIP More than 5 sec at below 200mbar or above 5000mbar 100%
ECT COLD After 1000 sec of engine running below 50°C of water temp 40%
ECT TRIP More than 110°C for more than 1,5seconds 60%
If at these RPM for more than 2sec we have oil pressure.
EOP TRIP 25%
1500rpm<800mbar/2000rpm<1400mbar/2500rpm<2000mbar
EOT COLD After 2000 sec of engine running below 50°C of oil temp 40%
EOT TRIP More than 142°C for more than 1,5seconds 60%
FP TRIP Less than 2500mbar for 2seconds 100%
KNOCK SHUTDOWN 5 cycles @ 6° retard or 2 cycles with Pre-Ignition events 50%
LEAN TRIP 100%
LIMP SWITCH ON 25%
OFF Everything OK 100%
PREIGN SHUTDOWN 50%
TIME ON LOAD LIMIT Tripped when Lambda >=1 & TPS>=50% & MAP>=1200mbar 25%
TRQ LIM TRIP 25%
VBAT TRIP Less than 10v for more than 2seconds 100%
VVT FAL More than 80°C for longer than 2,5 seconds 100%
Edition: 6

Hyundai i30 N TCR
5.9. Engine fire up
5.9.1. Engine fire up procedure
Fire Up Procedure
1 Turn on the main switch
2 Select the engine page on dash display using Alarm button on the steering wheel panel
3 Check that all the sensors (temperature and pressure) are working
4 Check engine oil level (see related chapter) and power steering oil level
Only cranking the engine using Start switch and Kill switch at the same time
5
The cranking is to build up the engine oil pressure to 2,5 bar
6 Start the engine without applying throttle pedal
Warm up engine to 80℃.
7 For endurance cars warm up the engine till the radiator fans activate at 90℃. Leave the engine
running until the fans turn off
th
Warm up the engine oil temperature to 50℃ then upshift from Neutral to 6 gear and down shift
8
to Reverse gear with engine 2000 rpm
Turn the steering wheel slowly to full lock and turn to opposite full lock. Do the steering at least 3
9
times to give pressure in the steering hydraulic system
10 Turn the engine off and set the coolant pressure to 0,8 bar
11 Check oil leaking and level
12 Check power steering oil level
5.9.2. Vital Parameter to Check
Vital Parameter Table

Parameter Chanel Range Remark
In the cold ambient condition, put tape
Engine coolant Min 65℃ - Max 90℃
ect on the front bumper grill to blank the
temperature Ideal temperature is 80℃
radiators
Engine coolant At idle with cold engine, the pressure is
ecp Min 1,9bar – Max 4,1bar
pressure increasing with coolant temperature
Min 50℃ - Max 115℃
Engine oil temp eot
Ideal temperature is 105℃
Engine oil Min 2,5bar – Max 6,0bar At idle with cold engine around 6 bar then
eop
pressure Ideal pressure is 5,0bar stabilize around 5,0 bar
Exhaust temp egt1 Max 900℃
Lambda lam1 0,825 – 0,86 @ WOT
Fuel pressure fpp 4,4 – 4,6 bar
Engine rpm rpm Max 7000rpm
Throttle pedal
ppsA 0% @ idle &100% @ WOT
position
Throttle valve
tps1 4°@ idle & 90°@ WOT
position
Battery voltage vbat Min 13,5 volts
Clutch pressure clpr 20,0bar 20,0bar at full travel of clutch pedal
Edition: 6

Hyundai i30 N TCR
5.10. Extra Connectors
Drink Pump
Connector T_CR10 Loom Chassis Rear Loom Spec REV4
Pin 01 12vDC Pin 02 GND Pin 03 -
Pin 04 - Pin 05 - Pin 06 -
Connector Type 2way 6,3 mm faston (Female Contacts)
Connector Mating 2way 6,3 mm faston (Male Contacts)
When DRINK button is pressed on the steering panel the output
Notes (pin1) is switched on.
Output trip 6A inrush 10A.
Radio
Pin 01 12vDC Pin 02 GND Pin 03 PTT+
Pin 04 PTT- Pin 05 - Pin 06 -
Connector Type DTM06-4S
Connector Mating DTM04-4P
12vDC is permanently switched on.
When RADIO button is pressed on the steering panel the PTT+ and
Notes
PTT- pins are shorted together.
Output is shared with Internal Electronics, trip 20A inrush 30A.
Spare CAN1
Pin 01 12vDC Pin 02 GND Pin 03 CAN1 H
Pin 04 CAN1 L Pin 05 Pin 06
In normal use the T_CT_Loom connector cap should be fitted.
Notes
This has the termination resistor inside.
Spare CAN2
In normal use the T_CT_Loom connector cap should be fitted. This
Notes
has the termination resistor inside.
Spare CAN3
Connector T_EE28 Loom Engine ECU Loom Loom Spec REV4
In normal use the T_CT_Loom connector cap should be fitted. This
Notes
has the termination resistor inside.
Edition: 6

Hyundai i30 N TCR
ECU Fan
Pin 01 12vDC Pin 02 GND Pin 03
Pin 04 Pin 05 Pin 06
Output will switch on when ECU temperature reaches 75°C.
Notes It will switch off again when ECU temperature drops below 70°C.
Spare In Eng.
Pin 01 5vDC Pin 02 GND Pin 03 Spare In Eng. 1
Pin 04 Spare In Eng. 2 Pin 05 12vDC Pin 06 ECU_OUT13
5vDC and 12vDC are permanently switched on.
5vDC is only to be used to power sensors.
Notes Spare In Eng. 1 and 2 are logged by the ECU data logging and are
available in the data.
Fuel #13 is currently not controlled.
Lap Beacon
Pin 01 12vDC Pin 02 GND Pin 03 Beacon In
Notes The Beacon In is a pull down input and so the beacon needs to
provide a GND pulse to trigger.
Application CAN
Connector T_CF10 Loom Chassis Front Loom Spec REV4
Pin 04 CAN1 L Pin 05 CAN3 H Pin 06 CAN3 L
The application CAN is used as a diagnostics port. It can also be
Notes
used to supply a 12vDC device.
Driver Fan
When DRIVER FAN button is pressed on the centre console panel
Notes the output (pin1) is switched on.
Edition: 6

Hyundai i30 N TCR
Spare Power
Notes It is shared with other spare power outlets.
Spare Power R
Spare Power
Connector T_CF25 Loom Chassis Rear Loom Spec REV5
Spare In CH.
Pin 01 5vDC Pin 02 GND Pin 03 Spare In Ch. 1
Pin 04 Spare In Ch. 2 Pin 05 Spare In Ch. 2 Pin 06 ECU_OUT11
5vDC and 12vDC are permanently switched on.
5vDC is only to be used to power sensors.
Notes Spare In CH. 1, 2 and 3 are logged by the ECU data logging and are
available in the data.
Fuel #11 is currently not controlled.
Edition: 6

Hyundai i30 N TCR
5.11. Gearbox Error Code
Xtrac error code

Channel XTerror
1 Position Sensor TOP failure
2 Position Sensor BOTTOM failure
4 Valve 1+2 amplifier error
8 Valve 3 amplifier error
Error code
16 Temperature too high
32 Barrel actuator blocked
64 Voltage actuator too low
128 No direction select
Edition: 6

Hyundai i30 N TCR
6. SETUP ADJUSTMENTS
6.1. Setup sheet (base setup on delivery)
Figure 64. Setup sheet (Sprint race setting)
Edition: 6

Hyundai i30 N TCR
Hyundai I30 TCR Set up

Customer Responsible of Assembly Chassis Driver Destination Country Date
Da Silva Acacio
Transmission
Gearbox Type XTRAC-1046-TCR30 Oil Neo 75w90 Volume 1.5 litres
Differential α/β 30/45 Friction Faces 8+8 Preload 85 Nm
Clutch master cylinder [mm] Brembo D17.64 (58135-5G01) Fluid Brembo HTC64T
Engine
Base Type TCR-#33 Air Filter BMC
Fans Water N/A Coils Bosch P65 (inductive)
Fuel Type PANTA TCR Oil SHELL 0W 40
Steering Oil type Shell Spirax S4 ATF HDX [Lts] 1.75 litres
Brakes & Handbrake
Brake balance [bar] Front 20.0 Rear 16.0
Damper and Springs
160-60-100 (51102-TS21) 160-60-100 (51102-TS21)

Main spring [N/mm]
160-60-80 (51102-TS01) 160-60-80 (51102-TS01)
60-60-5 (51103-TS01) 60-60-5 (51103-TS01)

Helper spring [N/mm]
60-60-5 (51103-TS01) 60-60-5 (51103-TS01)
Ohlins (54107-TS21) Ohlins (54107-TS21)
Damper fitted Den.
Ohlins (54108-TS21) Ohlins (54108-TS21)
Compression Rebound Compression Rebound
Damper setting Clicks 14 clicks 8 clicks 14 clicks 8 clicks
8 clicks 6 clicks 8 clicks 6 clicks
Roll bar Front Ø22X2t (51812-TS11) Position Soft Soft Rear Ø22X2t (51812-TS11) Position Medium Medium
Wheel Spacer [mm] 15 (5mm + 5mm + 5mm) 8 (5mm + 3mm)
Geometry
Rim Type Braid 18X10 ET35 (PCD5X114.3) Material Aluminium
Tyre Type Hankook W52 [bar] 2.0
Design Measured Design Measured
Camber [°] - 4.00° -4.1° - 4.00° -4.1°
- 3.50° -3.5° - 3.50° -3.5°
Front Camber shims (Left / Right) [mm] 5.5mm (2mm+2mm+2.5mm) 5.0mm 5.5mm (2mm+2mm+2.5mm) 5.0mm
Real castor [°] - -
Design Measured Design Measured

Toe [mm] 0.5mm (0.4°) Out 0.5mm 0.5mm (0.4°) Out 0.5mm
0 0
Target wheelbase (Left / Right) [mm] 2678 2678
Weight & Ride Height
Ballast configulation [kg] LHS 30 RHS/F 50 RHS/R 15
404.0 400.5
Corner weight [kg]
(Car + Ballast + Driver + Fuel) 270.5 272.5
Total weight / Front % [kg / F%] 1347.5 59.7%
Cross % / Left %
[%] Cross [%] 49.80% Left [%] 50.06%
Design Measured
Spring position [mm] 49 49 53.0 55.0

96 96 92.0 92.0
78 78 78.0 78.0
Ride height (Driver + Fuel) [mm]
315 315 315.0 314.0
Bodywork & Aero
Rear Wing Type TCR Homologated Wing Angle [°] 0.0°
Front Splitter Type Standard Ride height [mm] 82.0mm
Fuel in [Litre] 5 litres
Figure 65. Setup sheet (Endurance race setting)
Edition: 6

Hyundai i30 N TCR
6.2. Ride height adjustments
6.2.1. Ride height measuring point
Measuring Points – Front
 Measure from the flat spot on the

sub frame, as shown in the picture
 Front ride height measuring point is

the lowest point of the car
Measuring Points – Rear
 Measure from the flat spot on the sub

frame, as shown in the picture
Edition: 6

Hyundai i30 N TCR
6.3. Dampers
6.3.1. Damper setting

Damper adjusters on the EXT (standard and high spec 1) are fully closed when turned fully clockwise.
The position “0” is fully closed in bump and rebound adjusters.
The adjusters on the Ohlins damper are fully closed when the adjuster is fully turned clockwise.
Damper Alterative
Damper Option Damper Adjustment
Fully clockwise Fully close (Hard)
EXT S i30N TCR Standard
Fully anti-clock wise Fully open (soft)
Fully clockwise Fully close (stiff)
EXT Hs i30N TCR High Spec 1
Fully anti-clock wise Fully open (soft)
Ohlins TX46CS Fully clockwise Fully close (Hard)
High Spec 2
/ TTX36 Fully anti-clock wise Fully open (soft)
Figure 66. EXT Standard i30N TCR Adjustments
Edition: 6

Hyundai i30 N TCR
Figure 67. EXT High Spec i30N TCR Adjustments
Figure 68. Ohlins High Spec i30N TCR Adjustments
Edition: 6

Hyundai i30 N TCR
Figure 69. EXT Hs Front Bump Damper Curves
Edition: 6

Hyundai i30 N TCR
Figure 70. EXT Hs Front Rebound Damper Curves
Edition: 6

Hyundai i30 N TCR
Figure 71. EXT Hs Rear Bump Damper Curves
Edition: 6

Hyundai i30 N TCR
Figure 72. EXT Hs Rear Rebound Damper Curves
Edition: 6

Edition: 6
Hyundai i30 N TCR
Comp. 0 Rbnd. 0
Comp. 4 Rbnd. 4
Comp. 8 Rbnd. 8
Comp. 12 Rbnd. 12
Comp. 16 Rbnd. 16
Comp. 20 Rbnd. 20
Comp. 22 Rbnd. 22
Hyundai i30 N TCR User Manual

Figure 73. Ohlins TTX46CS Front Damper Curves
109
Hyundai i30 N TCR
Rbnd. 20
Rbnd. 10
Rbnd. 15
Rbnd. 25
Rbnd. 5
Rbnd. 0
Comp. 10
Comp. 15
Comp. 20
Comp. 25
Comp. 0
Comp. 5
Figure 74. Ohlins TTX46CS Rear Damper Curves
Edition: 6

Hyundai i30 N TCR
6.4. Anti-roll bars
6.4.1. Anti-roll Bar Adjustment

There are three different diameters of ARB’s for the Front and three for the Rear (see chart below). The
same anti-roll bar can be used for the front and the rear.
There are also three adjustments to be made, by different positions for the drop link on the anti-roll
bar arm.
Figure 75. Anti-roll bar setting position
Anti-roll Bar Adjustments

Front Rear
Anti-roll bar Soft Ø18 X 2,0 Ø18 X 2,0
Anti-roll bar Medium Ø22 X 2,0 (Standard) Ø22 X 2,0 (Standard)
Anti-roll bar Stiff Ø25 X 2,3 Ø25 X 2,3
Figure 76. Front anti-roll bar stiffness @ wheel, standard setup is 100%
Edition: 6

Hyundai i30 N TCR
Figure 77. Rear anti-roll bar stiffness @ wheel, standard setup is 100%
Edition: 6

Hyundai i30 N TCR
6.5. Alignment
6.5.1. Camber
Front suspension camber angle is adjustable with changing the camber shim configurations. Please
note that at least 3,0mm wheel spacer has to be applied from camber angle -4,5° to avoid the contact
between wheel and strut.
Front Camber Chart

Camber Shims Wheel Spacer (Minimum)
-3,5° 2mm + 2mm + 2,5mm -
-4,0° 2mm + 2mm + 1,5mm -
-4,5° 2mm + 1mm + 1,5mm 3,0mm
-5,0° 2mm + 1,5mm 5,0mm
-5,5° 2,5mm 3,0mm + 3,0mm
-6,0° 1,5mm 5,0mm + 3,0mm
Edition: 6

Hyundai i30 N TCR
6.6. Suspension Geometry
Please be advised the front and rear suspension geometry characteristics as below chart. The (-) sign
in the wheel travel is bump, and (+) sigh means rebound.
Front suspension kinematic specification (Left wheel)

Wheel Travel Camber -4,5° Camber -3,5°
(mm) Camber ° Toe ° Motion Ratio Camber ° Toe ° Motion Ratio
-70 -5,081 0,13 1,009 -4,169 0,101 1,013
-63 -5,069 0,117 1,017 -4,145 0,092 1,021
-56 -5,045 0,104 1,025 -4,111 0,083 1,029
-49 -5,01 0,09 1,033 -4,067 0,073 1,037
-42 -4,964 0,077 1,041 -4,013 0,063 1,045
-35 -4,909 0,064 1,048 -3,949 0,053 1,052
-28 -4,845 0,051 1,056 -3,876 0,042 1,06
-21 -4,771 0,038 1,063 -3,794 0,032 1,067
-14 -4,689 0,025 1,07 -3,704 0,021 1,074
-7 -4,599 0,012 1,077 -3,606 0,011 1,081
0 -4,5 0 1,083 -3,5 0 1,087
6 -4,409 -0,01 1,089 -3,403 -0,009 1,093
12 -4,313 -0,02 1,094 -3,301 -0,018 1,098
18 -4,211 -0,03 1,1 -3,193 -0,027 1,103
24 -4,104 -0,04 1,105 -3,081 -0,036 1,108
30 -3,992 -0,05 1,11 -2,963 -0,046 1,113
36 -3,875 -0,059 1,115 -2,841 -0,055 1,118
42 -3,752 -0,068 1,12 -2,714 -0,064 1,123
48 -3,625 -0,077 1,124 -2,582 -0,073 1,127
54 -3,494 -0,086 1,129 -2,445 -0,083 1,132
60 -3,357 -0,095 1,133 -2,304 -0,092 1,136
Figure 78. Front suspension kinematic characteristics
Please be advised the front and rear suspension geometry characteristics as below chart. The (-) sign
in the wheel travel is bump, and (+) sigh means rebound.
Edition: 6

Hyundai i30 N TCR
Rear suspension kinematic specification (Left Wheel)

Wheel Travel Outer hole in the subframe – RCH 100 Inner hole in the subframe – RCH 120
(mm) Camber ° Toe ° Motion Ratio Camber ° Toe ° Motion Ratio
-70 -6,795 -0,02 0,963 -7,095 0,015 0,99
-63 -6,539 -0,006 0,963 -6,805 0,026 0,988
-56 -6.29 0,005 0,962 -6,522 0,034 0,987
-49 -6,046 0,013 0,962 -6.246 0,038 0,985
-42 -5,808 0,018 0,962 -5,976 0,039 0,984
-35 -5,577 0,02 0,962 -5,714 0,038 0,983
-28 -5,35 0,02 0,962 -5,458 0,034 0,981
-21 -5,13 0,018 0,961 -5.209 0,028 0,98
-14 -4,915 0,013 0,961 -4,966 0,02 0,979
-7 -4,705 0,007 0,961 -4,73 0,011 0,978
0 -4,5 0 0,962 -4,5 0 0,977
6 -4,329 -0,007 0,961 -4,308 -0,01 0,976
12 -4,161 -0,016 0,961 -4,12 -0,021 0,975
18 -3,996 -0,024 0,961 -3,937 -0,032 0,975
24 -3,836 -0,034 0,961 -3,758 -0,043 0,974
30 -3,679 -0,044 0,961 -3,583 -0,055 0,973
36 -3,525 -0,054 0,961 -3,413 -0,067 0,972
42 -3,374 -0,065 0,961 -3.247 -0,078 0,971
48 -3.227 -0,075 0,96 -3,085 -0,09 0,97
54 -3,083 -0,086 0,96 -2,927 -0,101 0,969
60 -2,942 -0,097 0,96 -2,773 -0,111 0,967
Figure 79. Rear suspension kinematic characteristics
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Hyundai i30 N TCR
6.7. Aerodynamics
6.7.1. Aerodynamic Adjustment

The angle of rear wing assembly is adjustable by setting holes on the wing support. And adjust the rear
wing side plate angle to keep flat through the slot on the wing side plate. Rear wing inclination angle is
affected by the body pitch angle. Please measure the body pitch angle on the top surface of the fuel
cell cover. The wing profile adjustment range is +/-10° and wing side plate angle adjustment range is
+/-8° as below Figure 81.
And check the fixation condition of all the aerodynamic parts periodically.
Figure 80. Rear wing profile angle adjustment
Rear wing angle

Fixation Point Inclination Angle Fixation Point Inclination Angle
① -2,5° ⑤ +2,5°
② -5,0° ⑥ +5,0°
③ -7,5° ⑦ +7,5°
④ -10,0° ⑧ +10,0°
Figure 81. Rear wing side plate angle adjustment
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Hyundai i30 N TCR
6.7.2. Aerodynamic Setting Effect

The aerodynamic effect of the rear wing angle inclination angle and front and rear ride height is
demonstrated following chart. The aero dynamic setting Please note that (+) values are less down
force and (–) values are more down force in the lift coefficient.
Rear wing
Wing Inclination CD CL CL-F CL-R
0,0° 0,409 -0,44 -0.22 -0.21
+2,5° 0,417 -0,46 -0.22 -0.25
+5,0° 0,426 -0,49 -0.21 -0.27
+7,5° 0,433 -0,50 -0.20 -0,30
+10,0° 0,439 -0,51 -0.20 -0,31
Down force with different ride height (Base setup splitter height 82mm, wing 0,0°)
Front ride height Rear ride height CD CL-F CL-R
Base Base 0,409 -0.22 -0.21
Base -5,0mm 0,410 -0.20 -0.22
Base -10,0mm 0,408 -0,16 -0.23
-5,0mm Base 0,406 -0,18 -0.22
-5,0mm -5,0mm 0,406 -0,19 -0.22
-5,0mm -10,0mm 0,404 -0,17 -0.22
-10,0mm Base 0,401 -0.22 -0.20
-10,0mm +5,0mm 0,401 -0.29 -0,18
-10,0mm +10,0mm 0,403 -0,38 -0,15
-15,0mm +20,0mm 0,406 -0,55 -0,10
-15,0mm +15,0mm 0,406 -0,70 -0,06
-15,0mm +10,0mm 0,404 -0,82 -0,02
-15,0mm -5,0mm 0,400 -0,88 0,00
-15,0mm -10,0mm 0,392 -0,91 0,02
-15,0mm -15,0mm 0,383 -0,92 0,03
-20,0mm +20,0mm 0,385 -1,13 0,09
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Hyundai i30 N TCR
7. TOOLING
7.1. Alignment tool
You can place order the alignment tool with below part number. Please contact sales department for
detailed information.
Alignment tool
Item Part Number
Toe-bar set 09415-TS01
Setup wheels 09416-TS01
Figure 82. Front toe bar installation
Figure 83. Rear toe bar installation
Edition: 6

Hyundai i30 N TCR
Figure 84. Set up wheel
7.2. Gearbox tool
You can place order the gearbox tool with below part number. Please contact sales department for
detailed information.
Gearbox tool
Item Part Number
Cluster Setting Jig 1046-999-002B
Cluster Stand Assy 1046-999-003A
Differential Setting Tool 516-999-001A
Differential Removal Tool 516-999-005A
Differential End Cap Tightening Tool 516-499-003B
Differential Preload Setting Tool 406-499-004B
Differential Holding Tool 516-499-002A
Edition: 6

Hyundai i30 N TCR
8. LIFING
All kms listed as below are to be treated as approximate and actual kms achieved will vary on
maintenance, driving style and other factors.
Sprint component lifing

Unit Description Action Mileage (km) Remark
Engine Rebuild 7000
Turbo Replace 2500
Spark plugs Replace 2500
Alternator belt Replace 2500
Exhaust Replace 9000
Engine Catalytic Converter Replace 9000
Engine oil Replace Each event
Oil filter Replace Each event
Air filter Service Each event
High pressure fuel pump Service 9000
Fuel pumps and filter Service 5000
Transmission oil Service Each event
Transmission oil filter Service Each event
Clutch Replace 2 events Check wear after each event
nd rd
Gear ratios 2 / 3 gear Replace 2400 Crack check every 2 events
th th
Gear ratios 5 / 6 gear Replace 3200 Crack check every 2 events
Clutch shaft Replace 6400 Crack check every 4 events
Gearbox
Layshaft Replace 3200/40 starts Crack check every 2 events
Dog rings Replace 3200 Crack check every 2 events
Mainshaft Replace 6400 Crack check every 4 events
Final drive Replace 3200 Crack check every 4 events
Cross shaft Replace 3200 Crack check every 4 events
Driveshaft Replace 2400 Crack check every 2 events
Damper Front & Rear Service 5000 Check after each event
Hub Front & Rear Service 2500
Suspension Wishbone assy Front & Rear Service 2500
Upright Front Replace 10000
Upright Rear Replace 5000
Steering Steering rack Service 5000
Caliper Front & Rear Service 5000
Brake
Master cylinder Service 5000
Edition: 6

Hyundai i30 N TCR
Endurance component lifing

Unit Description Action Mileage (km) Remark
Engine Rebuild 9000 Every 2 endurance (24h) races
Turbo Replace 5000
Spark plugs Replace 5000
Alternator belt Replace 5000
Exhaust Replace 9000
Engine Catalytic Converter Replace 9000
Engine oil Replace 5000
Oil filter Replace 5000
Air filter Service Each event
High pressure fuel pump Service 9000
Fuel pumps and filter Service 5000
Transmission oil Service 5000
Transmission oil filter Service 5000
Clutch Replace 7000 Check wear after each event
Gear ratios Replace 5000 Crack check every event
Clutch shaft Replace 5000 Crack check every event
Gearbox Layshaft Replace 5000 Crack check every event
Dog rings Replace 5000 Crack check every event
Mainshaft Replace 7000 Crack check every event
Final drive Replace 7000 Crack check every event
Cross shaft Replace 7000 Crack check every event
Driveshaft Replace Each event Crack check every event
Damper Front & Rear Service 5000 Check after each event
Hub Front & Rear Service 5000
Suspension Wishbone assy Front & Rear Service 5000
Upright Front Replace 10000
Upright Rear Replace 5000
Steering Steering rack Service 5000
Caliper Front & Rear Service 5000
Brake
Master cylinder Service 5000
Edition: 6

Hyundai i30 N TCR
9. ATTACHMENTS
9.1. TCR Technical Form order procedure
TCR technical form is compulsory document to take part in each TCR series authorized by WSC Ltd.
The form must be delivered in original, signed and stamped on each page. Reproduction of this
document, TCR technical forms in a whole or in part, is prohibited. WSC reserve the right to withdraw
the TCR Technical forms, if any version of reproduction is found.
The team fills out the form in the order form and sends the form to form@tcr-series.com. The form in
this document is sample, so please fill out the original order form is available from the FTP server.
Edition: 6

Hyundai i30 N TCR
Edition: 6

Hyundai i30 N TCR
9.2. Gearbox Drawings
The following drawings can be downloaded in full format from our ftp server.
Figure A1. Dressed Maincase Assembly
Edition: 6

Hyundai i30 N TCR
Figure A2. Dressed Maincase Assembly
Edition: 6

Hyundai i30 N TCR
Figure A3. Gearbox Assembly
Edition: 6

Hyundai i30 N TCR
Figure A4. Gearbox Assembly
Edition: 6

Hyundai i30 N TCR
Figure A5. Maincase Assembly
Edition: 6

Hyundai i30 N TCR
Figure A6. Maincase Assembly
Edition: 6

Hyundai i30 N TCR
Figure A7. Cluster Housing Assembly
Edition: 6

Hyundai i30 N TCR
Figure A8. RH Output Flange Assy - CV
Edition: 6

Hyundai i30 N TCR
Figure A9. Clutch Shaft Assembly
Edition: 6

Hyundai i30 N TCR
Figure A10. Selector Fork Assembly
Edition: 6

Hyundai i30 N TCR
Figure A11. AGS Detent Assembly
Edition: 6

Hyundai i30 N TCR
Figure A12. Plate Differential Assembly
Edition: 6

Hyundai i30 N TCR
Figure A13. Differential Cassette Assembly
Edition: 6

Hyundai i30 N TCR
Figure A14. Pump Assembly
Edition: 6

Hyundai i30 N TCR
Figure A15. Cluster Assembly – 6 Speed
Edition: 6

Hyundai i30 N TCR
Figure A16. Cluster Setting Jig Assembly
Edition: 6

Hyundai i30 N TCR
Figure A17. Cluster Stand Assembly
Edition: 6

Hyundai I30 TCR - Manual - Edition6

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Hyundai I30 TCR - Manual - Edition6

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Hyundai i30 N TCR

1. CONTACT INFORMATION ..................................................................................................................... 5

2. TECHNICAL INFORMATION .................................................................................................................. 6

2.1. General car data .................................................................................................................................. 6

3. WORKSHOP MAINTENANCE ................................................................................................................ 8

3.1. Engine ................................................................................................................................................... 8

Hyundai i30 N TCR User Manual 1

3.10. Headlights .......................................................................................................................................... 33

4.1. Switch Panel ...................................................................................................................................... 48

5.1. Dash Keypad ...................................................................................................................................... 51

Hyundai i30 N TCR User Manual 2

5.6.1. Instruction ................................................................................................................................. 69

6. SETUP ADJUSTMENTS ...................................................................................................................... 100

6.1. Setup sheet (base setup on delivery) ........................................................................................... 100

Hyundai i30 N TCR User Manual 3

6.7.1. Aerodynamic Adjustment...................................................................................................... 116

7. TOOLING ............................................................................................................................................ 118

7.1. Alignment tool ................................................................................................................................. 118

8. LIFING ................................................................................................................................................. 120

9. ATTACHMENTS .................................................................................................................................. 122

9.1. TCR Technical Form order procedure .......................................................................................... 122

Hyundai i30 N TCR User Manual 4

Car Sales & Commercial Enquiries

Andrew Johns ajohns@hyundai-ms.com +49 (0) 6023 9929 431

Veronica Boni vboni@hyundai-ms.com +49 (0) 6023 9929 434

Timo Hadzibeganovic thadzibeganovic@hyundai-ms.com +49 (0) 6023 9929 437

Federico Lancini FLancini@hyundai-ms.com +49 (0) 6023 9929 436

Andrea Cisotti acisotti@hyundai-ms.com +49 (0) 6023 9929 457

Jihun Park jhpark@hyundai-ms.com +49 (0) 6023 9929 438

Nicolas Schwartz nschwartz@hyundai-ms.com +49 (0) 6023 9929 432

Miguel Freitas mfreitas@hyundai-ms.com +49 (0) 6023 9929 429

Andrea Maselli amaselli@hyundai-ms.com +49 (0) 6023 9929 433

Joseph Hunt jhunt@hyundai-ms.com +49 (0) 151 6495 6274

TCR username HMSGCTCR

TCR password CustomerRacing-TCR

Hyundai Motorsport GmbH, Junker Strasse,

Hyundai i30 N TCR User Manual 5

2.1. General car data

Engine identification THETA II T-GDI (G4KH)

Cylinder capacity 1999,6 cm3

Bore & stroke 86,0mm x 86,0mm

Maximum rpm 7000 rpm

Electronic control unit Liferacing engine management system

Fuel tank capacity 100 litres

Oil system Wet Sump

Differential Salisbury plate type with adjustable external preload

Shifter Pneumatic paddle shift on steering wheel

Clutch AP racing hydraulic 2 plates clutch

Damper 2-way adjustable, ride height adjustable

Anti-roll bar Roll stiffness adjustable (Soft / Medium / Hard)

Disc (Front / Rear) Brembo Ø380mm ventilated / Brembo Ø 278mm ventilated

Brake pads Pagid brake pads

Brake balance Front & rear brake balance adjustable

Pedal system Hyundai Motorsport bespoke pedal system

Hand brake Hydraulic handbrake with mechanical locking

Hyundai i30 N TCR User Manual 6

2.2. Dimensions and weight

Wheelbase 2678 ±10 mm

Overhang front 957 ±10 mm