engine Seat Ibiza 5D 2009 Repair Manual

Checking and refilling levels179
Safety First
Controls and equipment
Practical tips
Technical Data
WARNING
All work on the engine or in the engine compartment, e.g. checking and
refilling fluids, involves the danger of injury and scalding as well as the risk
of accident or fire.•Never open the bonnet if you see steam, smoke or coolant escaping
from the engine compartment. Otherwise, there is a risk of sustaining
burns. Wait until no more steam or coolant is emitted, then allow the
engine to cool before carefully opening the bonnet.•Switch off the engine and remove the key from the ignition.•Apply the handbrake and move the gear stick to neutral or selector
lever to position P.•Keep children away from the vehicle.•Never touch hot engine parts. There is a risk of burns.•Never spill liquids on a hot engine or on a hot exhaust gas system. This
is a fire hazard.•Avoid causing short-circuits in the electrical system, particularly at the
points where the jump leads are attached ⇒page 220. The battery could
explode.•Never touch the radiator fan. It is temperature controlled and could
start automatically, even when the engine has been switched off and the
key removed from the ignition!•Do not unscrew the cap on the expansion tank when the engine is hot.
If the coolant is hot, the cooling system will be pressurised!•Protect face, hands and arms by covering the cap with a large, thick
cloth to protect against escaping coolant and steam.•A l w ays ma ke s u re yo u ha v e n o t l e f t a n y obj e c ts , s u ch as c l ea n in g cl o t h s
and tools, in the engine compartment.•If you have to work underneath the vehicle, you must use suitable
stands additionally to support the vehicle, there is a risk of accident!. A
hydraulic jack is insufficient for securing the vehicle and there is a risk of
injury.
•If any work has to be performed when the engine is started or with the
engine running, there is an additional, potentially fatal, safety risk from the
rotating parts, such as the drive belts, alternator, radiator fan, etc., and
from the high-voltage ignition system. You should also observe the
following points:
−Never touch the electrical wiring of the ignition system.
− Ensure that jewellery, loose clothing and long hair do not get
trapped in rotating engine parts. Danger of death. Before starting any
work remove jewellery, tie back and cover hair, and wear tight-fitting
clothes.
− Always think carefully about pressing the accelerator if a gear is
engaged in either an automatic or manual gearbox. The vehicle could
move, even if the handbrake is applied. Danger of death.•If work has to be carried out on the fuel system or on electrical compo-
nents, you must observe the following safety notes in addition to the above
warnings:
−Always disconnect the battery. The vehicle must be unlocked when
this is done, otherwise the alarm will be triggered.
− Do not smoke.
− Never work near naked flames.
− Always have a fire extinguisher on hand.Caution
When changing or topping up service fluids, make absolutely certain that you
fill the fluids into the correct reservoirs. Failure to observe this point will result
in serious malfunctions and engine damage!
WARNING (continued)
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Checking and refilling levels
180
For the sake of the environmentService fluids leaks are harmful to the environment. For this reason you
should make regular checks on the grou nd underneath your vehicle. If you
find spots of oil or other fluids, have your vehicle inspected in a qualified
workshop.Opening the bonnet
The bonnet is released from inside the vehicle.
Before opening the bonnet ensure that the windscreen wipers are in
rest position.
– To release the bonnet, pull the lever under the dashboard ⇒fig. 113 in the direction indicated (arrow). The bonnet will be
released by a spring action ⇒.
– Lift the bonnet using the release lever (arrow) and open the bonnet.
– Release the bonnet stay and secure it in fixture designed for this
in the bonnet.
WARNING
Hot coolant can scald!•Never open the bonnet if you see steam, smoke or coolant escaping
from the engine compartment.
Fig. 113 Bonnet opening
lever
Fig. 114 Bonnet support
rod
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Checking and refilling levels181
Safety First
Controls and equipment
Practical tips
Technical Data
•Wait until no more steam, smoke or coolant is emitted from the bonnet,
then carefully open the bonnet.•When working in the engine compartment, always observe the safety
warnings ⇒page 178.
Closing the bonnet– Slightly raise the bonnet
– Release the bonnet stay and replace it in its support.
– At a height of about 30 cm let it fall so it is locked.If the bonnet does not close, do not press downwards. Open it once more and
let it fall as before.
WARNING
If the bonnet is not closed properly, it could open while you are driving and
completely obscure your view of the road. Risk of accident.•After closing the bonnet, always check that it is properly secured. The
bonnet must be flush with the surrounding body panels.•If you notice that the bonnet latch is not secured when the vehicle is
moving, stop the vehicle immediately and close the bonnet properly. Risk
of accident.
Engine oilEngine oil specifications
The engine oil used must conform with exact specifications.Specifications
The engine comes with a special, high quality, multi grade oil that can be
used in all seasons of the year except for those regions affected by extreme
cold.
As the use of good quality oil is necessary for the correct operation and long
service life of the engine, when it becomes necessary to replenish or change
the oil, always use an oil that complies to the VW standards.
If it is not possible to find oil conforming to the VW standards then oil
conforming to the ACEA or API standards with an appropriate viscosity at
atmospheric temperature should be used instead. The use of this type of oil
may have some repercussions on the performance of the engine for example,
long starting time, increased consumption and a higher emission level.
If a top up is required then different oils may be mixed as long as they all
conform to the VW standards.
The specifications (VW standards) set out in the following page should
appear on the container of the service oil; the container will display together
the different standards for petrol and diesel engines, the oil can be used for
both types of engines.
WARNING (continued)
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Checking and refilling levels
182Oil 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
11). 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.Checking the engine oil level
The engine oil dipstick indicates the level of the oil.
Engine type
Specification
Petrol
VW 501 01/ VW 502 00/ VW 504 00
Diesel
VW 505 01/ VW 507 00/ VW 506 01
Diesel Engines with Particulate filter
(DPF)
a)
a)Only use recommended oils, otherwise you may damage the engine.
VW 507 00
Fig. 115 Types of oil
according to temperature
11)Viscosity: oil density
Fig. 116 Engine oil
dipstick
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Checking and refilling levels183
Safety First
Controls and equipment
Practical tips
Technical Data
Checking 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 ⇒ page 182,
fig. 116. Top up with engine oil if necessary.Oil level in area
–Do not add oil.
Oil level in area
–Oil can be topped up. The indicated oil level should be after the zone
Oil level in area
–Oil must be topped up. The indicated oil level should be after in zone
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. For this reason the engine oil level must be
checked at regular intervals, preferably when filling the tank and before a
journey.
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 178.
Caution
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 178.
– Unscrew cap from oil filler opening ⇒fig. 117 .
– Top-up oil in small amounts, using the correct oil.
AAAB
AA
AC
AA
AA
Fig. 117 In the engine
compartment: Engine oil
filler cap
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Checking and refilling levels
184
– 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 opening is shown in the corresponding engine
compartment illustration ⇒page 230.
Engine oil specification ⇒page 181.
WARNING
Oil is highly inflammable! Ensure that no oil comes into contact with hot
engine components when topping up.
Caution
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 a qualified work-
shop.
For the sake of the environment
The oil level must never be above area . Otherwise oil can be drawn in
through the crankcase breather and escape into the atmosphere via the
exhaust system.
Changing engine oil
The engine oil must be changed at the intervals given in the
service schedule.We recommend that you have the engine oil changed by an Authorised
Service Centre.
The oil change intervals are shown in the Maintenance Programme.
WARNING
Only change the oil yourself if you have the specialist knowledge required!•Before opening the bonnet, read and observe the warnings
⇒ page 178, “Safety instructions on working in the engine compartment”.•Wait for the engine to cool down. Hot oil may cause burn injuries.•Wear eye protection to avoid injuries caused by splashes of oil.•When removing the oil drain plug with your fingers, keep your arm hori-
zontal to help prevent oil from running down your arm.•Wash your skin thoroughly if it comes into contact with engine oil.•Engine oil is poisonous! Used oil must be stored in a safe place out of
the reach of children until it is disposed of.Caution
No additives should be used with engine oil. This could result in engine
damage. Any damage caused by the use of such additives would not be
covered by the factory warranty.
For the sake of the environment
•Because of the disposal problems, the necessary special tools and
specialist knowledge required, we recommend that you have the engine oil
and filter changed by an Authorised Service Centre.
AB
AA
AA
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Checking and refilling levels185
Safety First
Controls and equipment
Practical tips
Technical Data
•Never pour oil down drains or into the ground.•Use a suitable container when draining the used oil. It must be large
enough to hold all the engine oil.CoolantCoolant specifications
Coolant is a mixture of water and at least 40% coolant addi-
tive.The cooling system must be filled with a mixture of water and at least 40% of
our coolant additive G 12++ or an additive with the specification TT-VW 774 G
(recognised by its purple colour). This mixture gives the necessary frost
protection down to -25°C and protects the alloy parts of the cooling system
against corrosion. It also prevents scaling and raises the boiling point of the
coolant.
The concentration of coolant must always be at least 40% - even if frost
protection is not required.
If greater frost protection is required in very cold climates, the proportion of
the antifreeze additive G 12++ can be increased. However, the percentage of
coolant additives should not exceed 60%, as this would reduce the frost
protection. It would also reduce the cooling effect. A mixture with 60%
coolant additive will give frost protection to approximately -40°C.
WARNING
•The coolant additive is toxic. There is a toxic risk. Always keep the
coolant additive in the original container which should be stored out of the
reach of children. The same applies to coolant which you have drained off.
•The coolant additive G 12++ must be added in sufficient quantities to
provide anti-freeze protection at th e coldest ambient temperatures that
can be expected. At extremely cold ambient temperatures, the coolant
could freeze, causing the vehicle to breakdown. As the heater would also
not work in this situation, there is a risk of suffering exposure!Caution
•Other additives may give considerably inferior corrosion protection. The
resulting corrosion in the cooling system can lead to a loss of coolant,
causing serious damage to the engine.•If additive G12++ is not available, this can be mixed with G12+, bearing in
mind that the protection against corrosion will be reduced.WARNING (continued)
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Checking and refilling levels
186Checking 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 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 expansion tank and read off the coolant level. – If the level is below 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 reservoir is shown in the corresponding
engine compartment illustration ⇒ page 230.
Ensure the coolant conforms to the required specifications. Do not use a
different type of additive if coolant additive G 12++ is not available. In this
case use only water and bring the coolant concentration back up to the
correct level as soon as possible by topping up with the specified additive.
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 additive G 12++ can be mixed with the G 12+ in any proportion.
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 178.•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.
Fig. 118 In the engine
compartment: Coolant
expansion tank cap
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Checking and refilling levels187
Safety First
Controls and equipment
Practical tips
Technical Data
Caution
•If you notice a change in the colour of the liquid because it has been in
use for a long time, it should be changed, as it will have lost some of its prop-
erties and could cause damage to the vehicle.•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 cooling 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 the 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
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 178.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 fluids or soap solutions, the tiny holes
in the fan-shaped nozzles could become blocked.
Fig. 119 In the engine
compartment: Cap of
windscreen washer fluid
reservoir.
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Checking and refilling levels
190Brake 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 brake fluid reservoir is shown in the corresponding engine
compartment illustration ⇒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. However, 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 56.
WARNING
Before opening the bonnet to check the brake fluid level, read and observe
the warnings ⇒page 178.Changing the brake fluid
The Maintenance Program indicates the brake fluid change
intervals.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 178 in
“Working in the engine compartment”.
Brake fluid absorbs moisture. In the course 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.
It is important that you use only brake fluid compliant with 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. 122 In the engine
compartment: Brake fluid
reservoir cover
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