ESP Seat Cordoba 2006 Service Manual

Checking and refilling levels175
Safety First
Operating instructions
Tips and Maintenance
Te c h n i c a l D a t a
– Pull the dipstick out again and check the oil level ⇒ page 174,
fig. 120.
– Replace the dipstick, pushing it in as far as it will go.The position of the dipstick is shown in the corresponding engine compart-
ment diagram ⇒page 224.
If the oil level is in area ⇒page 174, fig. 120 , do not top up with oil.
If the oil level is in area , you may top up with oil (approx. 0.5 l).
If the oil level is in area , you mu st top up with oil (approx. 1.0 l).
It is normal for the engine to consume a certain amount of oil. Consumption
can be up to 1.0 litres per 1,000 km. For this reason the engine oil level must
be checked at regular intervals, prefer ably when filling the tank and before a
journey.
When the engine is working hard, for instance during sustained high-speed
motorway cruising in summer, when towi ng a trailer or climbing on mountain
passes, the oil level should preferably be kept within area and not above
this.
WARNING
Any work carried out in the engine compartment or on the engine must be
carried out cautiously.•
When working in the engine compartment, always observe the safety
warnings ⇒ page 169Caution
If the oil level is above the area do not start the engine. This could result
in damage to the engine and catalytic converter. Contact an Authorised
Service Centre.
Topping up engine oil

Top up gradually with small quantities of oil.Before opening the bonnet, read and observe the warnings ⇒ in
“Safety instructions on working in the engine compartment” on
page 169 .
– Unscrew cap from oil filler
opening ⇒ fig. 121.
– Top-up oi

l in small amounts, using the correct oil.
– To avoid over-filling with engine oil, you should top-up using small quantities, wait a while and check the oil level before
adding any more oil.
– As soon as the oil level is in area , carefully close the cap.
The position of the oil filler openi ng is shown in the corresponding engine
compartment diagram ⇒page 224.
AA
ABAC
AA
AA
Fig. 121 In the engine
compartment: Engine oil
filler cap
AB
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Checking and refilling levels
178
Opening the coolant expansion tank
– Switch off the engine and allow it to cool.
– To prevent scalding, cover the cap on the expansion tank with a thick cloth and carefully unscrew the cap ⇒ .
Checking coolant level
– Look into the open coolant ex pansion tank and read off the
coolant level.
– If the level is underneath the “MIN” mark, top up with coolant.
Topping up coolant
–Only use new coolant.
– Do not fill above the “MAX” mark.
Closing the coolant expansion tank
– Screw the cap on again tightly.The position of the coolant expansion tank is shown in the corresponding
engine compartment diagram ⇒page 224.
Make sure that the coolant meets the required specifications ⇒page 177.
Do not use a different type of additive if coolant additive G 12+ is not avail-
able. In this case use only water and bring the coolant concentration back up
to the correct level as soon as possible by putting in the specified additive
⇒ page 177.
Always top up with new coolant.
Do not fill above the “MAX” mark. Otherwise the excess coolant will be forced
out of the cooling system when the engine is hot. The coolant additive G 12+ (dyed purple
) may be mixed with G 12 (dyed red)
and also with G 11.
WARNING
Any work carried out in the engine compartment or on the engine must be
carried out cautiously.•
When working in the engine compartment, always observe the safety
warnings ⇒page 169
•
When the engine is warm or hot, the cooling system is pressurised! Do
not unscrew the cap on the expansion tank when the engine is hot. This is
a burn injury risk.Caution
•
When mixed with other additives the colour of G 12 will change to brown.
If this occurs you should have the coolant changed immediately. Failure to do
so will result in engine damage!
•
If a lot of coolant has been lost, wait for the engine to cool down before
putting in cold coolant. This avoi ds damaging the engine. Large coolant
losses are an indication of leaks in the cooling system. See a specialised
workshop immediately and have the cooling system checked. Otherwise,
there is a risk of engine damage.
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Checking and refilling levels
182Brake fluidChecking the brake fluid level
The brake fluid is checked at the intervals given in the service
schedule.– Read off the fluid level at the transparent brake fluid reservoir. It
should always be between the “MIN” and “MAX” marks.The position of the coolant expansion tank is shown in the corresponding
engine compartment diagram ⇒page 224. The brake fluid reservoir has a
black and yellow cap.
The brake fluid level drops slightly when the vehicle is being used as the
brake pads are automatically adjusted as they wear. However, if the level goes down noticeab
ly in a short time, or drops below the
“MIN” mark, there may be a leak in the brake system. A display on the instru-
ment panel will warn you if the brake fluid level is too low ⇒page 60.
WARNING
Before opening the bonnet to check the brake fluid level, read and observe
the warnings ⇒page 169.Changing the brake fluid
The brake fluid must be renewed every two years.We recommend that you have the brake fluid changed by an Authorised
Service Centre.
Before opening the bonnet, please read and follow the warnings ⇒ in
“Safety instructions on working in the engine compartment” on page 169 in
“Working in the engine compartment”.
Brake fluid absorbs moisture. In the cour se of time, it will absorb water from
the ambient air. If the water content in the brake fluid is too high, the brake
system could corrode. This also consider ably reduces the boiling point of the
brake fluid. Heavy use of the brakes may then cause a vapour lock which
could impair the braking effect.
For this reason the brake fluid must be renewed every two years.
It important that you use only use brake fluid compliant with the US standard
FMVSS 116 DOT 4. We recommend the use of Genuine SEAT brake fluid.
WARNING
Brake fluid is poisonous. Old brake fluid impairs the braking effect.
Fig. 126 In the engine
compartment: Brake fluid
reservoir cover
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Checking and refilling levels
184charge. Never short the battery terminals. High-energy sparks can cause
injury.•
A highly explosive mixture of gases is given off when the battery is
under charge. The batteries should be charged in a well-ventilated room
only.
•
Keep children away from acid and batteries.
•
Before working on the electrical system, you must switch off the
engine, the ignition and all consumers. The minus cable on the battery
must be disconnected. When a light bulb is changed, you need only switch
off the light.
•
Deactivate the anti-theft alarm by unlocking the vehicle before you
disconnect the battery! The alarm will otherwise be triggered.
•
When disconnecting the battery from the vehicle electrical system,
disconnect first the negative cable and then the positive cable.
•
Switch off all electrical consumers before reconnecting the battery.
Reconnect first the positive cable and then the negative cable. Never
reverse the polarity of the connections. This could cause an electrical fire.
•
Never charge a frozen battery, or one which has thawed. This could
result in explosions and chemical burns. Always replace a battery which
has frozen. A flat battery can freeze at temperatures around 0
°C.
•
Ensure that the vent hose is always connected to the battery.
•
Never use a defective battery. This may be fatally explosive. Replace a
damaged battery immediately.Caution
•
Never disconnect the battery if the ignition is switched on or if the engine
is running. This could damage the electrical system or electronic compo-
nents.
•
Do not expose the battery to direct sunlight over a long period of time, as
the intense ultraviolet radiation can damage the battery housing.
•
If the vehicle is left standing in cold conditions for a long period, protect
the battery from frost. If it “freezes” it will be damaged.
Checking the electrolyte level
The electrolyte level should be checked regularly in high-
mileage vehicles, in hot countries and in older batteries.– Open the bonnet and open the battery cover at the front ⇒ in
“Safety instructions on working in the engine compartment” on
page 169 ⇒ in “Warnings on handling the battery” on
page 183.
– Check the colour display in the magic eye on the top of the battery.
– If there are air bubbles in the window, tap the window gently until they disperse.The position of the battery is show n in the corresponding engine compart-
ment diagram ⇒page 224.
The round window (“magic eye”) on the top of the battery changes colour,
depending on the charge level and electrolyte level of the battery.
If the colour in the window is colourless or bright yellow, the electrolyte level
of the battery is too low. Have the battery checked by a qualified workshop.
The colours green and black are used by the workshops for diagnostic
purposes.
WARNING (continued)
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Checking and refilling levels
186New tyres
New tyres have to be run in ⇒page 143.
The tread depth of new tyres may vary, according to the type and make of tyre
and the tread pattern.
Concealed damage
Damage to tyres and rims is often not readily visible. If you notice unusual
vibrations or the car pulling to one side, this may indicate that one of the tyres
is damaged. The tyres should be checked immediately by an Authorised
Service Centre.
Tyres with directional tread pattern
An arrow on the tyre sidewall indicates the direction of rotation on tyres with
directional tread. Always observe the direction of rotation indicated when
fitting the wheel. This guarantees optimum grip and helps to avoid aqua-
planing, excessive noise and wear.
WARNING
•
New tyres do not have maximum grip in the first 500 km. Drive particu-
larly carefully to avoid risk of accident.
•
Never drive with damaged tyres. This may be an accident risk.
•
If you notice unusual vibration or if the vehicle pulls to one side when
driving, stop the vehicle immediately and check the tyres for damage.
Checking tyre pressure
The correct tyre pressure can be seen on the sticker on the
inside of the tank flap.1. Read the required tyre inflatio n pressure from the sticker. The
values refer to Summer tyres. For Winter tyres, you must add 0.2
bar to the values given on the sticker.
2. The tyre pressures should only be checked when the tyres are cold. The slightly raised pressures of warm tyres must not be
reduced.
3. Adjust the tyre pressure to the load you are carrying.Tyre pressure
The correct tyre pressure is especially important at high speeds. The pressure
should therefore be checked at least once a month and before starting a
journey.
WARNING
A tyre can easily burst if the pressure is too low, causing an accident!•
At continuously high speeds, a tyre with insufficient pressure flexes
more. In this way it becomes too hot, and this can cause tread separation
and tyre blow-out. Always observe the recommended tyre pressures.
•
If the tyre pressure is too low or too high, the tyres will wear prema-
turely and the vehicle will not handle well. Risk of accident!For the sake of the environment
Under-inflated tyres will increase fuel consumption.
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If and when
192
– Engage the first gear, or put the selector lever to position P for
those vehicles with an automatic gearbox.
– If you are towing a trailer, unhitch it from your vehicle.
– Take the vehicle tools and the spare wheel out of the luggage
compartment.
WARNING
Put the hazard warning lights on and pl ace the warning triangle in position.
This is for your own safety and also warns other road users.
Caution
If you have to change the tyre on a gradient, block the wheel opposite the
wheel being changed by placing a stone or similar object under it to prevent
the vehicle from rolling away.
Note
Please observe legal requirements when doing so.Changing a wheelChange the wheel as described below
– Remove the wheel cover. Also refer to page 193, fig.
–Slacken the wheel bolts.
– Raise the car with the jack in the corresponding zone –
Ta k e o f f the wheel and then put on the spare wheel
– Lower the vehicle.
– Tighten the wheel bolts firmly in diagonal sequence with the box
spanner
–Replace the cover .
After changing a wheel
After changing the wheel there are still tasks to complete.– Put the tools and jack back in the luggage compartment.
– Place the wheel with the defective tyre in the luggage compart-
ment and secure it.
– Check the tyre pressure of the newly fitted tyre as soon as possible.
– Have the tightening torque of the wheel bolts checked as soon as possible with a torque wrench. The prescribed torque is 120 Nm.
Note•
If you notice that the wheel bolts are corroded and difficult to turn when
changing a wheel, they must be replaced before having the wheel bolt torque
checked.
•
In the interest of safety, drive at moderate speeds until the wheel bolt
torque has been checked.
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If and when
200
22 Main beam headlight, left 10
23 Number plate light/si de light indicator 5
24 Rear windscreen wiper 10
25 Injectors(fuel) 10
26 Brake light switch /ESP (Turn sensor) 10
27 Instrument panel/Diagnosis 5
28 Unit: glovebox light, boot light, interior light 10
29 Climatronic 5
30 Power supply central locking unit 5
31 Left front window control 25
32 Vacant
33 Self powered alarm horn 15
34 Engine control unit 15
35 Sunroof 20
36 Engine ventilator heating /blower 25
37 Headlight washer pump 20
38 Front and rear fog lights 15
39 Engine control unit (petrol) 15
40 Engine control unit diesel + SDI Fuel pump 30
41 Fuel gauge 15
42 Ignition transformer+ Engine control unit T70 15
43 Dipped headlight (right side) 15
44 Left rear window control 25
45 Front right window control 25
Number
Electrical equipment Amperes
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If and when217
Safety First
Operating instructions
Tips and Maintenance
Te c h n i c a l D a t a
Towing and tow-startingTo w - s t a r t i n g *
The use of jump leads is preferable to tow-starting.We recommend that you do not tow-start your vehicle. Jump-starting
is preferable ⇒page 214.
However, if your vehicle has to be tow-started:
–Engage the 2
nd or the 3
rd gear.
– Keep the c
lutch pressed down.
– Switch on the ignition.
– Once both vehicles are mo ving, release the clutch.
– As soon as the engine starts, press the clutch and move the gear- stick into neutral. This helps to prevent driving into the towing
vehicle.
WARNING
The risk of accidents is high when tow-starting. The vehicle being towed
can easily collide with the towing vehicle.
Caution
When tow-starting, fuel could enter the catalytic converter and damage it.
Towing eyesPlease observe the following points if you use a tow-rope:
Notes for the driver of the towing vehicle
– Drive slowly at first until the tow-rope is taut. Then accelerate gradually.
– Begin and change gears cautiously. If you are driving an auto- matic vehicle, accelerate gently.
– Remember that the brake servo and power steering are not working in the vehicle you are towing. Brake earlier than you
would normally, but with a more gentle pressure on the brake.
Notes for the driver of the towed vehicle
– Ensure that the tow-rope remains taut at all times when towing.
Fig. 157 Towing eye at
the front of the vehicle
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If and when
218
Fitting the front towing eye
– First remove the right hand cover from the lower part of the bumper.
–Remove screw ⇒page 217, fig. 157 .
– Take the towing ring and the wheel spanner out of the vehicle tool kit.
– Turn the ring to the left with the box spanner until it is correctly screwed in.
– To remove the ring, turn to the right with the box spanner. Tow-rope or tow-bar
It is easier and safer to tow a vehicle with a tow-bar. You should only use a
tow-rope if you do not have a tow-bar.
A tow-rope should be slightly elastic to reduce the loading on both vehicles.
It is advisable to use a tow-rope made of synthetic fibre or similarly elastic
material.
Attach the tow-rope or the tow-bar only to the towing eyes provided or a
towing bracket.
Driving style
Towing requires some experience, especially when using a tow-rope. Both
drivers should be familiar with the te chnique required for towing. Inexperi-
enced drivers should not attempt to tow-start or tow away another vehicle.
Do not pull too hard with the towing vehicle and take care to avoid jerking the
tow-rope. When towing on an unpaved ro ad, there is always a risk of over-
loading and damaging the anchorage points.
The ignition of the vehicle being towed must be switched on to prevent the
steering wheel from locking and also to allow the use of the turn signals,
horn, windscreen wipers and washers. As the brake servo does not work if the
engine is not running, you must apply
considerably more pressure to the brake pedal than you normally would.
As the power assisted steering does not work if the engine is not running, you
will need more strength to steer than you normally would.
Towing vehicles with an automatic gearbox
•
Put the selector lever into position “N”.
•
Do not drive faster than 50 km/h when towing a vehicle.
•
Do not tow further than 50 km.
•
If a breakdown vehicle is used, the vehicle must be towed with the front
wheels raised.Note
•
Observe legal requirements when towing or tow-starting.
•
Switch on the hazard warning lights of both vehicles. However, observe
any regulations to the contrary.
•
For technical reasons, vehicles with an automatic gearbox must not be
tow-started.
•
If damage to your vehicle means that there is no lubricant in the gearbox,
you must raise the drive wheels while the vehicle is being towed.
•
If the vehicle has to be towed more than 50 km, the front wheels must be
raised during towing, and towing should be carried out by a qualified person.
•
The steering wheel is locked when the vehicle has no electrical power. The
vehicle must then be towed with the front wheels raised. Towing should be
carried out by a qualified person.
Rear towline anchorageAt the rear, on the right below th e rear bumper is a towline point.
AA
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General notes on the technical data
222WeightsKerb weight refers to the basic model with a fuel tank filled to 90% capacity
and without optional extras. The figure quoted includes 75 kg to allow for the
weight of the driver.
For special versions and optional equipment fittings or for the addition of
accessories, the weight of the vehicle will increase ⇒.
WARNING
•
Please note that the centre of gravity may shift when transporting
heavy objects; this may affect the vehi cle's handling and lead to an acci-
dent. Always adjust your speed and dr iving style to suit road conditions
and requirements.
•
Never exceed the gross axle weight rating or the gross vehicle weight
rating. If the allowed axle load or the allowed total weight is exceeded, the
driving characteristics of the vehicle may change, leading to accidents,
injuries and damage to the vehicle.
To w i n g a t r a i l e rTrailer weightsTrailer weights
The trailer weights and drawbar loads approved are selected in intensive
trials according to precisely defined criteria. The approved trailer weights are
valid for vehicles in EU for maximum speeds of 80 km/h (in certain circum-
stances up to 100 km/h). The figures may be different in other countries. All
data in the official vehicle documents take precedence over these data ⇒. Drawbar load
The
maximum permitted weight exerted by the trailer drawbar on the ball joint
of the towing bracket must not exceed 75 kg.
In the interest of road safety, we recommend that you always tow
approaching the maximum drawbar load. The response of the trailer on the
road will be poor if th e drawbar load is too small.
If the maximum permissible drawbar load cannot be met (e.g. with small,
empty and light-weight single axle trailers or tandem axle trailers with an axle
base of less than 1 metre), at least 4% of the actual trailer weight is a legal
stipulation for a drawbar load.
WARNING
•
For safety reasons, you should not drive at speeds above 80 km/h when
towing a trailer. This also applies to countries where higher speeds are
permitted.
•
Never exceed the maximum trailer weights or the draw bar loading. If
the permissible axle load or the perm issible total weight is exceeded, the
driving characteristics of the vehicle may change, leading to accidents,
injuries and damage to the vehicle.
WheelsTyre pressure, snow chains, wheel boltsTyre pressures
The sticker with the tyre pressure values can be found on the inside of the
tank flap. The tyre pressure values given there are for cold tyres. The slightly
raised pressures of warm tyres must not be reduced ⇒.
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