engine Seat Exeo ST 2009 Repair Manual

Checking and refilling levels227
Safety First
Controls and equipment
Practical tips
Technical Data
WARNING
Never open the bonnet if you see steam or drips of coolant being released
from t he engine com par t ment . Fail ure to com ply could resul t in burns . Wait
until no steam or coolant can be seen before opening the bonnet.Work in the engine compartment
Extra caution is necessary when working on components in
the engine compartment.Always be aware of the danger of injury and scalding as well as the risk of
accident or even fire when working in the engine compartment (e.g. when
checking and refilling fluids). Therefore, always observe the warnings listed
below and follow all general safety precautions. The engine compartment of
any motor vehicle is a potentially hazardous area ⇒.
WARNING
•Switch the engine off.•Remove the ignition key.•Apply handbrake firmly.•If your vehicle is equipped with a manual gearbox, place the gearshift
lever in neutral. If you are driving an automatic vehicle, place the selector
lever in the position P.•Wait for the engine to cool down.•Children should not be allowed to approach the engine compartment•Never spill liquids involved in vehicle operations on the engine
compartment, as these may catch fire (e.g. anti-freeze containing liquid
coolant).
•Take care not to cause short circuits in the electrical system, especially
when working on the battery.•Never touch the radiator fan while the engine is hot, as the fan could
start up suddenly.•Never open the expansion tank when the engine is hot. The cooling
system is under pressure.•Protect face, hands and arms from any hot steam or hot liquid coolant
released by covering the cap with a large, thick rag when opening the
expansion tank.•If any tests have to be performed with the engine running, there is an
extra safety risk from the rotating parts, such as the drive belts, alternator
and radiator fan, etc., and from the high-voltage ignition system.•Observe the following additional warnings if work on the fuel system or
the electrical system is necessary:
−Always disconnect the battery.
− Do not smoke.
− Never work near open flames
− Always keep an approved fire extinguisher immediately available.Caution
When topping up fluids, make sure the correct fluid is put into the correct
filler opening. This can otherwise cause serious malfunctions or engine
damage.
For the sake of the environment
Inspect the ground underneath your vehicle regularly so that any leaks are
detected at an early stage. If you find spots of oil or other fluids, have your
vehicle inspected in the garage.
WARNING (continued)
ExeoST_EN.book Seite 227 Donnerstag, 3. September 2009 12:24 12

Checking and refilling levels
228
NoteOn right-hand drive vehicles some of the containers/ reservoirs mentioned
below are located on the other side of the engine compartment.Closing the bonnet– To close the bonnet, pull it down to overcome the spring pres- sure.
– Leave the bonnet secured in the locking part. Do not tighten
⇒ .
WARNING
•For safety reasons the bonnet must always be completely closed when
the vehicle is moving. After closing it always check that it is properly
secured. The bonnet must be flush with the adjacent body panels.•Should you notice that the bonnet is not safely secured when the
vehicle is moving, stop the vehicle immediately and close the bonnet.
Failure to do so could result in an accident.
Engine oilGeneral notesWe recommend that the oil change should be performed by an Authorised
Service Centre or a qualified workshop, according to the Maintenance
Program. The correct oil specifications for your engine are listed in the
⇒page 229,
“Oil properties”.
Check that the specifications quoted (VW standards) appear on the container
either singly or in combination with other specifications.
Flexible maintenance intervals (Extended Service Intervals*)
Special lubricating oils have been de ve lop
ed in the framework of the SEAT
Booklet “Extended Se rvice Intervals” Maintenance Programme
⇒ page 229.
This typ

e of oil must be used if you intend to take advantage of the prolonga-
tion of the maintenance intervals in the framework of the “Extended Service
Intervals” program.
•Do not mix the LongLife oil with oil intended for fixed service intervals, as
the requirements for the extended service intervals are then no longer guar-
anteed.•Only in exceptional circumstances, if the engine oil level is too low
⇒ page 230 and LongLife oil is not available, it is permitted to top up (once)
with oil for fixed service intervals ⇒ page 229 (up to a maximum of 0.5
litres).
Fixed service intervals*
If “Extended Service Intervals” are not applied to your vehicle, you can use
oils for fixed service intervals ⇒ page 229. In this case, your vehicle must be
serviced after a fixed interval of 1 year / 15,000 km (10,000 miles) (see the
Maintenance Program).•In exceptional circumstances, if the engine oil level is too low
⇒ page 230 and you cannot obtain the oil specified for your vehicle, you can
put in a small quantity of oil conforming to the specification ACEA A2 or
ACEA A3 (petrol engines) or ACEA B3 or ACEA B4 (diesel engines) (up to 0.5l).
Vehicles with diesel particulate filter*
The Maintenance Program states whether your vehicle is fitted with a diesel
particulate filter.
ExeoST_EN.book Seite 228 Donnerstag, 3. September 2009 12:24 12
⇒

Checking and refilling levels229
Safety First
Controls and equipment
Practical tips
Technical Data
•Vehicles with a diesel particulate filter must only b e fille d with VW 507 00
engine oil.•Avoid mixing this oil with other engine oils.•Only in exceptional circumstances, if the engine oil level is too low
⇒ page 230 and you cannot obtain the oil specified for your vehicle, can you
put in a small quantity of oil (once) conforming to the VW 506 00, VW 506 01,
VW 505 00, VW 505 01 or ACEA B3 / ACEA B4 specification. (up to 0.5l).Oil propertiesViscosity
The viscosity class of the oil is selected according to the diagram.
When the ambient temperature falls outside the limits of the scale for a short
period, an oil change is not required. Mono-grade oil
Single grade oils are generally not suitable for all year round use, due to
ranges of viscosity
3).
These oils are only useful in a climate that is constantly very cold or very
warm.
Engine oil additives
No type of additive should be mixed with the engine oil. The deterioration
caused by these additives is not covered by the warranty.
Note
Before a long trip, we recommend finding an engine oil that conforms to the
corresponding VW specifications and keeping it in the vehicle. This way, the
correct engine oil will always be available for a top-up if needed.
Fig. 178 Types of oil
according to temperature
Engine type
Specification
Petrol
VW 502 00/ VW 504 00
Diesel Engines with Particu-
late filter (DPF)
a)
a)Only use recommended oils, otherwise you may damage the engine.
VW 507 00
Extended Service Intervals*
Engine type
Specification
Petrol
VW 504 00
Diesel
VW 507 00
3)Viscosity: oil density
ExeoST_EN.book Seite 229 Donnerstag, 3. September 2009 12:24 12

Checking and refilling levels
230Checking the oil levelChecking oil level
– Park the vehicle in a horizontal position.
– Briefly run the engine at idle speed until the service temperature
is reached then stop.
– Wait two minutes.
– Pull out the dipstick. Wipe the dipstick with a clean cloth and insert it again, pushing it in as far as it will go.
– Then pull it out once more and check the oil level ⇒fig. 179 . If
the oil level is too low, add more engine oil ⇒page 230.
Oil level in area
–Do not top up oil. Oil level in area
–Oil
can be topped up. After topping up the oil level should be in
area .
Oil level in area
–Oil must be topped up. After topping up the oil level should be in
area .
Depending on how you drive and the conditions in which the car is used, oil
consumption can be up to 0.5 l/1,000 km. Oil consumption is likely to be
higher for the first 5,000 km. Therefore, the engine oil level must be checked
at regular intervals, preferably when filling the tank and before a journey.Topping up the engine oil

–Unscrew cap

from oil filler opening ⇒page 295, fig. 246 .
Fig. 179 Markings on oil
dipstick
Aa
Ab
Aa
Ac
Aa
Fig. 180 In the engine
compartment: Engine oil
filler cap
ExeoST_EN.book Seite 230 Donnerstag, 3. September 2009 12:24 12

Checking and refilling levels231
Safety First
Controls and equipment
Practical tips
Technical Data
– Carefully fill with the specified grade of oil ⇒page 229, adding
0.5 litres at a time.
– After two minutes, check the oil level once again ⇒page 230.
– Where necessary, add more engine oil.
– Replace the oil filler cap carefully and push the dipstick all the way in.
WARNING
•When refilling with oil, make sure no oil falls onto hot engine parts.
Failure to comply could result in fire.•Wash your skin thoroughly if it comes into contact with engine oil.Caution
•The oil level must never be above area . This could damage the cata-
lytic converter or the engine. Contact a specialist garage to drain the engine
oil if necessary.•No additives should be used with engine oil. Any damage caused by the
use of such additives would not be covered by the factory warranty.For the sake of the environment
•Oil must not be disposed of into the drains or onto the ground.•Always observe legal requirements when disposing of empty oil
canisters.
Cooling systemLiquid coolant
The purpose of the liquid coolant is to carry heat away from
the engine. The correct amount of antifreeze is decisive in
preventing the cooling system from freezing in winter.The your vehicle's engine cooling system is filled for life at the factory, so no
coolant needs to be changed. The liquid coolant consists of a mixture of water
and anti-freeze G12++. This is a glycol-based antifreeze with anti-corrosion
additives.
Liquid coolant additive
The amount of antifreeze required depends on the temperatures to be
expected in the winter season. If the antifreeze concentration is too low the
coolant can freeze, resulting in failure of the cooling system and heater.
The cooling system is filled at the factory with the correct amount of anti-
freeze for the country concerned.
In most cases, the mixture consists of 60% water and 40% anti-freeze . This
mixture gives the required anti-freeze protection at temperatures down to -
25°C and particularly protects the metal parts of the cooling system against
corrosion. It also prevents scaling and significantly raises the boiling point of
the liquid coolant.
Countries with warm climate
The liquid coolant concentration must not be reduced by adding plain water,
even in the summer or in warm climates. The concentration of the anti-freeze
must always be at least 40%.
Countries with cold climate
If greater frost protection is required in very cold climates, the proportion of
the anti-freeze G12++ can be increased. A concentration of 60% offers anti-
Aa
ExeoST_EN.book Seite 231 Donnerstag, 3. September 2009 12:24 12

Checking and refilling levels
232freeze protection of temperatures down to approx. -40°C. However,the
concentration of anti-freeze must not exceed 60%, as the anti-freeze protec-
tion would then drop and the performance of the coolant system would suffer.
Vehicles for countries with cold climates (e.g. Sweden, Norway and Finland)
have factory-filled anti-freeze protection for temperatures down to -35°C. In
these countries, the concentration of anti-freeze should always be at least
50%.
Caution
•It is advisable to have the cooling system checked before the winter
season to make sure that the antifreeze concentration is adequate for the
conditions to be expected. This applies particularly if you intend to take the
car into a colder climate zone. If necessary, have the antifreeze concentration
increased to 50 - 60% as required.•Use only anti-freeze G12++ , an additive meeting the “TL-VW 774G” spec-
ification. Other anti-freezes may give considerably inferior corrosion protec-
tion. The damage caused by the use of these anti-freezes may lead to a loss
of liquid coolant, causing serious damage to the engine.•The anti-freeze G12++ can be mixed only with anti-freeze additives G11,
G12 and G12+.
Checking the liquid coolant level
The liquid coolant level can be checked at a glance.– Switch the ignition off.
– Check the coolant level on liquid coolant expansion tank ⇒fig. 181 . When the engine is cold, it should be between the
“min” and “max” marks. When the engine is hot, it may be
slightly above the “max” mark.Its location is shown in the corresponding general overview of the engine
compartment.
The liquid coolant level should be checked with the engine switched off.
The liquid coolant level is monitored by a warning lamp in the instrument
panel ⇒ page 78. However, we recommend that it should be checked occa-
sionally.
Fig. 181 Engine compart-
ment: Liquid coolant
deposit
ExeoST_EN.book Seite 232 Donnerstag, 3. September 2009 12:24 12

Checking and refilling levels233
Safety First
Controls and equipment
Practical tips
Technical Data
Liquid coolant losses
Any loss of liquid coolant normally indicates a
leak in the cooling system. In
this case the cooling system should be inspected by a specialist garage
without delay. It is not sufficient merely to top up the liquid coolant.
If there are no leaks in the system, a loss of liquid coolant can only occur if
the coolant boils and is forced out of the system as a result of overheating.
Caution
Radiator sealants must not be added to the liquid coolant. Such additives
could seriously impair the function of the cooling system.Topping up the liquid coolant
Be careful when topping up with liquid coolant.– Switch the engine off.
– Wait for the engine to cool down.
– Cover the cap on the expansion tank ⇒page 232, fig. 181 with a
cloth, and carefully unscrew the cap anti-clockwise ⇒.
– Add liquid coolant.
– Screw on the cap tightly.Make sure that the liquid coolant meets the required specifications
⇒page 231, “Liquid coolant”. Do not use a different type of anti-freeze if
anti-freeze G12++ is not available. In this case, use only water and bring the
anti-freeze concentration back up to the correct level as soon as possible.
Always top up with new liquid coolant. Do not fill above the “max” mark. Excess liquid coolant is forced out of the
system through the valve in the filler cap when the engine gets hot.
If a lot of liquid coolant has been lost, wait for the engine to
cool down before
putting in cold coolant. Failure to do so could result in serious engine
damage.
WARNING
•The cooling system is under pressure. Do not unscrew the cap on the
expansion tank when the engine is hot. Failure to comply could result in
burns.•The anti-freeze and liquid coolant can be a health hazard. Therefore,
the anti-freeze should be stored in the original container in a safe place out
of reach of children. Failure to comply could result in poisoning.For the sake of the environment
Drained off coolant should not be used again. Drain off the used coolant into
a suitable container and dispose of it in the proper manner (observe environ-
mental regulations).Radiator fan
The radiator fan can start running spontaneously.The auxiliary fan can continue to run for as long as 10 minutes after stopping
the engine – even after the ignition is switched off. It may also start running
suddenly ⇒ after some while if•stored heat raises the coolant temperature, or•the hot engine compartment is additionally heated up by the sun.
ExeoST_EN.book Seite 233 Donnerstag, 3. September 2009 12:24 12

Checking and refilling levels
234
WARNING
when working in the engine compartment be aware that the radiator fan
may start running suddenly, leading to the risk of injury.Washer fluid and windscreen wiper bladesWindscreen washer system
Plain water on its own is not sufficient for the windscreen
washer system.The container for the windscreen washer contains the cleaning fluid for the
windscreen and the headlight washer system*. The container is located in the
engine compartment (front left). The fi ller cap is marked with the symbol

⇒ fig. 182 . The
capacity of the container is listed in ⇒page 295.
Plain water on its own is not enough to clean the glass properly. It is therefore
advisable to add a suitable washer fluid additive (with wax solvent) to the
water. A washer fluid with freeze-resistant additive should be used in winter.
Caution
•Never put radiator anti-freeze or other additives into the windscreen
washer fluid.•Never use washer fluid which contains paint thinners or solvents as it can
damage the paintwork.
Fig. 182 In the engine
compartment: Cap of
windscreen washer fluid
reservoir.
ExeoST_EN.book Seite 234 Donnerstag, 3. September 2009 12:24 12

Checking and refilling levels237
Safety First
Controls and equipment
Practical tips
Technical Data
Removing the wiper blade
– Lift the wiper arm away from the glass ⇒ page 236, fig. 185.
– Slide the blade adapter in the di rection of the arrow and remove
the blade ⇒ page 236, fig. 185 .
Fitting the wiper blade
– With one hand, hold the top end of the wiper arm.
– Place the blade as shown in the ⇒ page 236, fig. 186 and slide
the adapter along until it engages.Check the condition of the wiper blad e regularly. Change as required.
If the windscreen wiper scrapes, i t s h o u l d b e r e p la ce d i f d a m a ge d , o r c l ea n e d
if soiled.
If this is not sufficient, refer to a qualified workshop.
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
•A damaged or dirty window wiper could scratch the rear window.•Never use fuel, nail varnish remover, paint thinner or similar products to
clean the window.•Never move the windscreen wiper by hand. This could cause damage.
Brake fluidChecking the brake fluid level
The brake fluid level can be checked at a glance.The brake fluid level must be between the “Min” and “Max” ⇒fig. 187 mark-
ings.
The fluid level may drop slightly after a period of time due to the automatic
compensation for brake pad wear. This is quite normal.
H owe ve r, if th e le ve l goes d own not icea bly i n a short time, or drops below the
“Min” mark, there may be a leak in the brake system. If the fluid level in the
reservoir is too low, this will be indicated by the brake warning lamp
⇒ page 70 and ⇒page 77. If this should happen, take the car to a qualified
workshop immediately and have the brake system inspected.
Fig. 187 Engine compart-
ment: markings on brake
fluid reservoir
ExeoST_EN.book Seite 237 Donnerstag, 3. September 2009 12:24 12

Checking and refilling levels239
Safety First
Controls and equipment
Practical tips
Technical Data
Winter operations
The battery is drained more in cold weather, which means that the starting
power is reduced. For this reason, have the battery checked and charged if
necessary before the start of winter.
Replacing the battery
A replacement battery
must have the same capacity, voltage and current
rating. It must also have the same dimensions as the original, factory-fitted
battery and have sealed caps. The SEAT batteries which have been specially
developed fulfil the maintenance, performance and safety specifications for
your vehicle.
We recommend you use maintenance-free batteries.
WARNING
•All work on batteries requires specialist knowledge. If work is required
on the battery, this should be performed by a Technical Service or
specialist garage. Danger of caustic burns and explosion!•The battery must not be opened. Never try to change the battery's
liquid level. Explosive gas is released from the battery that could lead to an
explosion.Caution
•The battery holder and clamps must always be correctly secured.•Before starting any work on the battery, always observe the warnings
listed under ⇒.For the sake of the environment
 Batteries contain toxic substances including sulphuric acid and lead.
Therefore, they must be disposed in line with environmental regulations and
must not be disposed of with ordinary household waste. Make sure discon-
nected batteries cannot tip over. Sulphuric acid could be spilt!
Important safety warnings for handling a car batteryThe battery is located at the back of the engine compartment ⇒ page 295.
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.
Wear eye protection

Battery acid is very corrosive and caustic. Wear protective
gloves and eye protection!

Fires, sparks, naked lights and smoking are prohibited!

A highly explosive mixture of gases is released when the batter y
is under charge.

Keep children away from acid and batteries!
ExeoST_EN.book Seite 239 Donnerstag, 3. September 2009 12:24 12