engine Seat Cordoba 2007 Repair Manual

Checking and refilling levels
180Checking the coolant level and topping up

The correct coolant level is important for fault-free func-
tioning of the engine cooling system.Before opening the bonnet, read and observe the warnings ⇒ in
“Safety instructions on working in the engine compartment” on
page 172.
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 expansion tank and read 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 re servoir is shown in the corresponding
engine compartment diagram ⇒page 230.
Make sure that the coolant meets the required specifications ⇒page 179.
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 179.
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 172.
Fig. 125 In the engine
compartment: Coolant
expansion tank cap
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Checking and refilling levels181
Safety First
Operating instructions
Tips and Maintenance
Te c h n i c a l D a t a
•
When the engine is warm or hot, the cooling system is pressurised! Do
not unscrew the cap on the expansion t ank 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 avoids damaging the engine. Large coolant
losses are an indication of leaks in the cooling system. See a specialised
workshop immediately and have the c ooling system checked. Otherwise,
there is a risk of engine damage.
Washer fluid and windscreen wiper bladesTopping up washer fluid

The water for cleaning the windscreen should always be
mixed with washer fluid.The windscreen washer and the headlight washing system are supplied with
fluid from the windscreen washer fluid container in the engine compartment.
The container holds approx. 2 litres; in vehicles with headlamp washers* it
holds approx. 4.5 litres.
The reservoir is located on the right-hand side of the engine compartment.
Plain water is not enough to clean th e windscreen and headlights. We recom-
mend that you always add a product to the windscreen washer fluid.
Approved windscreen cleaning products exist on the market with high deter-
gent and anti-freeze properties, these may be added all-year-round. Please
follow the dilution instructions on the packaging.
WARNING (continued)
Fig. 126 In the engine
compartment: Cap of
windscreen washer fluid
reservoir.
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Checking and refilling levels
182
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 172.Caution
•
Never put radiator anti-freeze or other additives into the windscreen
washer fluid.
•
Always use approved windscreen cleansing products diluted as per
instructions. If you use other washer fl uids or soap solutions, the tiny holes
in the fan-shaped nozzles could become blocked.
Changing windscreen wiper blades
If the windscreen wiper blades are in perfect condition, you
will benefit from improved visibility. Damaged wiper blades
should be replaced immediately.Removing the wiper blade
– Lift the windscreen wiper arm.
– Press on the securing tab.
– Extract the wiper blade from the wiper arm.
Fitting the wiper blade
– Insert the wiper blade onto the windscreen wiper arm until it clicks into place.
– Make sure that the blade faces down when fitting a blade with integrated deflector blade.
Fig. 127 Change wind-
screen wiper blade
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Checking and refilling levels183
Safety First
Operating instructions
Tips and Maintenance
Te c h n i c a l D a t a
If the
windscreen wipers smear , they should be replaced if they are damaged,
or cleaned if they are soiled.
If this does not produce the desired results, the setting angle of the wind-
screen wiper arms might be incorrect. They should be checked by a qualified
workshop and corrected if necessary.
WARNING
Do not drive unless you have good visibility through all windows!•
Clean the windscreen wiper blades and all windows regularly.
•
The wiper blades should be changed once or twice a year.Caution
•
Damaged or dirty windscreen wipers could scratch the windscreen.
•
Never use fuel, nail varnish remover, paint thinner or similar products to
clean the windows. This could damage the windscreen wiper blades.
•
Never move the windscreen wiper or windscreen wiper arm manually. This
could cause damage.Note
•
The wiper arms can be moved to the service position only when the
bonnet is properly closed.
Brake fluidChecking the brake fluid level
The brake fluid is checked at the intervals given in the service
schedule.– Read the fluid level at the transparent brake fluid reservoir. It should always be between the “MIN” and “MAX” marks.The position of the brake fluid reservoir is shown in the corresponding engine
compartment diagram ⇒page 230. 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.
Fig. 128 In the engine
compartment: Brake fluid
reservoir cover
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Checking and refilling levels
184However, if the level goes down noticeably 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 58.
WARNING
Before opening the bonnet to check the brake fluid level, read and observe
the warnings ⇒page 172.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 172 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 considerably 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 is 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.
•
Before opening the bonnet to check the brake fluid level, read and
observe the warnings ⇒page 172.
•
Brake fluid should be stored in the closed original container in a safe
place out of reach of children. There is a toxic risk.
•
Have the brake fluid changed every two years at the latest. Heavy use
of the brakes may cause a vapour lock if the brake fluid is left in the system
for too long. This would seriously affect the efficiency of the brakes and the
safety of the vehicle. This may cause an accident.Caution
Brake fluid could damage the paintwork. Wipe off any brake fluid from the
paintwork immediately.
For the sake of the environment
Brake fluid must be drained and disposed of in the proper manner observing
environmental regulations.
WARNING (continued)
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Checking and refilling levels185
Safety First
Operating instructions
Tips and Maintenance
Te c h n i c a l D a t a
BatteryWarnings on handling the battery
WARNING
Always be aware of the danger of injury and chemical burns as well as the
risk of accident or fire when working on the battery and the electrical
system:•
Wear eye protection. Protect your eyes , skin and clothing from acid and
particles containing lead.
•
Battery acid is very corrosive and caustic. Wear protective gloves and
eye protection. Do not tilt the batteries. This could spill acid through the
vents. Rinse battery acid from eyes immediately for several minutes with
clear water. Then seek medical care immediately. Neutralize any acid
splashes on the skin or clothing with a soapy solution, and rinse off with
plenty of water. If acid is swallowed by mistake, consult a doctor immedi-
ately.
•
Fires, sparks, naked lights and smoking are prohibited. When handling
cables and electrical equipment, avoid causing sparks and electrostatic charge. Never short the battery terminals. High-energy sparks can cause
injury.
•
A highly explosive mixture of gases is released 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 negative 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 alar m will otherwise be triggered.
•
When disconnecting the battery from the vehicle electrical system,
disconnect first the negative ca ble 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 that 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.

Wear eye protection

Battery acid is very corrosive and caustic. Wear protec-
tive gloves and eye protection!

Fires, sparks, naked lights and smoking are prohibited!

A highly explosive mixture of gases is released when the
battery is under charge.

Keep children away from acid and batteries!
WARNING (continued)
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Checking and refilling levels
186•
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 172 ⇒ in “Warnings on handling the battery” on
page 185.
– 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 shown in the corresponding engine compart-
ment diagram ⇒page 230.
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.
Charging and changing the vehicle battery
The battery is maintenance-free and is checked during the
inspection service. All work on the vehicle battery requires
specialist knowledge.If you often drive short distances or if the vehicle is not driven for long
periods, the battery should be checked by a qualified workshop between the
scheduled services.
If the battery has discharged and you have problems starting the vehicle, the
battery might be damaged. If this happens, we recommend you have the
vehicle battery checked by an Authorised Service Centre where it will be re-
charged or replaced.
Charging the battery
The vehicle battery should be charged by a qualified workshop only, as
batteries using special technology have been installed and they must be
charged in a controlled environment.
Replacing a vehicle battery
The battery has been developed to suit the conditions of its location and has
special safety features.
Genuine SEAT batteries fulfil the maintenance, performance and safety spec-
ifications of your vehicle.
WARNING
•
We recommend you use only maintenance-free or cycle free leak-proof
batteries that comply with the standards T 825 06 and VW 7 50 73. This
standard applies as of 2001.
•
Before starting any work on the batteries, you must read and observe
the warnings ⇒ in “Warnings on handling the battery” on page 185.
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If and when193
Safety First
Operating instructions
Tips and Maintenance
Te c h n i c a l D a t a
If and whenVehicle tools, spare wheelVeh icle To ols
The vehicle onboard tools are located under the floor panel in
the luggage compartment .– Lift floor panel
– Remove the tools or jack.The tool kit includes:•
Jack*
•
Hook for removing wheel covers or hub caps*
•
Box spanner for wheel bolts*
•
Reversible screwdriver with handle (i ncluding hexagonal interior) for the
wheel bolts. The screwdriver is a combination tool.
•
To wi ng e y e
•
Adapter for the anti-theft wheel bolts*
Some of the items listed are only provided on certain models / model years,
or are optional extras.
WARNING
•
Do not use the hexagonal socket in the screwdriver handle to tighten
the wheel bolts. It is impossible to tighten the bolts with the torque
required, risk of accident.
•
The jack supplied by the factory is only designed for changing wheels
on this model. On no account attempt to use it for lifting heavier vehicles
or other loads, risk of injury.
•
Use the jack only on firm, level ground.
•
Never start the engine when the vehicle is on the jack, risk of accident.
•
I f w o r k is t o b e ca r r i e d o ut un d e r n ea t h t h e v e h i cle , t h is m u st b e s e c ure d
by suitable stands. Otherwise, there is a risk of injury.
Compact temporary spare wheel*
If provided as part of the vehicle’s equipment, the compact
temporary spare wheel is only intended for temporary use
over short distances.The temporary spare wheel is stored under the floor panel in the luggage
compartment and is attached by a thumbnut.
How to use the compact temporary spare wheel
Should you ever have a punctured tyre, the compact temporary spare wheel
is only intended for temporary use until you can reach a workshop. The
standard-size road wheel should be replaced as soon as possible.
Please note the following restrictions when using the compact temporary
spare wheel. This spare wheel has been specially designed for your vehicle,
thus, it cannot be changed with the spare wheel from another vehicle.
No other type of tyre (normal summer or winter tyre) may be fitted on the
compact temporary spare wheel rim.
WARNING (continued)
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If and when
194Snow chains
For technical reasons, snow chains must not be used on the compact tempo-
rary spare wheel.
If you should have a puncture on one of the front wheels when using snow
chains, fit the compact temporary spare in place of one of the rear wheels.
You can then attach the snow chains to the wheel taken from the rear and use
this wheel to replace the punctured front wheel.
WARNING
•
The tyre pressures must be checked and corrected as soon as possible.
•
Do not drive faster than 80 km/h. H igher speeds can cause an accident.
•
Avoid heavy acceleration, hard brakin g and fast cornering, risk of acci-
dent.
•
Never use two or more compact spare tyres at the same time, risk of
accident.
•
No other type of tyre (normal summer or winter tyre) may be fitted on
the compact temporary spare wheel rim.
Tyre repair kit*
The tyre repair kit (for vehicles not including a spare wheel) is
stored under the floor panel in the luggage compartment.Your vehicle is equipped with the Tyre Mobility System “Tyre repair kit”.
The tyre repair kit consists of a container with sealing compound to repair the
puncture and a compressor to generate the required tyre pressure. The kit will
reliably seal punctures up to a size of about 4 mm caused by the penetration
of a foreign body into the tyre.
Note
•
Seek professional assistance if the repair of a tyre puncture is not
possible with the sealing compound.
Wheel changePreparation work
What you must do before changing a wheel.– If you have a flat tyre or puncture, park the vehicle as far away from the flow of traffic as possible. Choose a location that is as
level as possible.
– All passengers should leave the vehicle. They should wait in a
safe area (for instance behind the roadside crash barrier).
– Switch off the engine. Switch on the hazard warning lights.
–Apply the handbrake firmly.
– 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.
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If and when
204Fuses on left side of dash panelFuses
Number Electrical equipment Amperes
1 Secondary water pump 1.8 20 VT (T16) 15
2A BS/E S P 10
3 Vacant
4 Brake light, clutch switch, relay coils 5
5 Engine control unit (petrol) 5
6R ig h t s id e lig h t 5
7L eft s id e lig ht 5
8 Mirror heating unit 5
9 Lambda probe 10
10 Signal “S”
a). Radio unit 5
11 Electric mirror power supply 5
12 Headlamp height adjustment 5
13 Oil pressure/level sensor 5
14 Additional heati ng engine/fuel pump 10
15 Automatic gearbox unit 10
16 Heated seats 15
17 Engine control unit 5
18 Instrument panel /Heating and vent ilation, Navigation, Headlamp height adjustment, Electric mirror 10
19 Reverse light 10
20 Windscreen washer pump 10
21 Main beam headlight, right 10
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