brake Seat Toledo 2008 Service Manual

Your vehicle maintenance and cleaning205
Safety First
Operating instructions
Practical tips
Te c h n i c a l D a t a
Underbody maintenance
The vehicle underbody is coated to protect it from chemical
and mechanical damage.The protective coating can be damaged when driving. We recommend you to
ckeck the protective coating under the body and on the running gear, and
reinstated if necessary, before and after the winter season.
We recommend you to go to your Authorised Service Centre to carry out repair
work and additional anti-corrosion work.
WARNING
Do not apply underseal or anti-corrosion coatings to the exhaust pipes,
catalytic converter or the heat shields on the exhaust system. The heat of
the exhaust system or the engine could cause them to ignite! Fire hazard.Cleaning the engine compartment
Take special care when cleaning the engine compartment.Anti-corrosion treatment
The engine compartment and the surface of the power unit are given anti-
corrosion treatment at the factory.
Good corrosion protection is particularly important in winter when the car is
frequently driven on salted roads. To prevent the salt corroding the vehicle,
the entire engine compartment should be thoroughly cleaned before and
after winter.
Your Authorised Service Centre has got the necessary equipment to provide
the correct cleaning and preserving products. For this reason, we recommend
having this work performed by them. The anti-corrosion protection is usually removed if the engine compartment
is cleaned with grease remo
ving solutions, or if you have the engine cleaned.
On commissioning theis work, ensure that all surfaces, seams, joints and
components in the engine compartment are given anti-corrosion treatment.
WARNING
•
When working in the engine compartm ent, always observe the safety
warnings ⇒page 213.
•
Before opening the bonnet, switch the engine off, apply the parking
brake firmly and always remove the key from the ignition.
•
Allow the engine to cool before you clean the engine compartment.
•
Do not clean the vehicle underbody, wheel arches without protecting
your hands and arms. You may cut your self on sharp-edged metal parts.
Failure to comply could result in injury.
•
Moisture, ice and salt on the brakes may affect braking efficiency. Risk
of accident. Directly after washing, avoid sudden and sharp braking.
•
Never touch the radiator fan. It is temperature-controlled and could
start automatically, even when the key is removed from the ignition!For the sake of the environment
Fuel, grease and oil deposits could be removed when the engine is washed.
The polluted water must be cleaned in an oil separator. For this reason,
engine washing should be carried out on ly by a qualified workshop or a petrol
station.
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Checking and refilling levels213
Safety First
Operating instructions
Practical tips
Te c h n i c a l D a t a
Winter driving
Diesel can thicken in winter.Winter-grade diesel
When using “summer-grade diesel fuel”, difficulties may be experienced at
sub-zero temperatures because the fuel thickens due to wax separation.
Therefore, “winter-grade diesel fuel” is available in some countries during
the cold months. It can be used at temperatures as low as -22°C.
In countries with different climatic conditions the diesel fuel generally sold
has different temperature characteristics. Check with an Authorised Service
Centre or filling stations in the country concerned regarding the type of diesel
fuels available.
Filter pre-heater
Your vehicle is fitted with a fuel filter pre-heater, making it well equipped for
operation in winter. This ensures that the fuel system remains operational to
approx. -24°C, provided you use winter-grade diesel which is safe to -15°C.
However, if the fuel has waxed to such an extent that the engine will not start
at temperatures of under -24°C, simply place the vehicle in a warm place for
a while.
Caution
Do not mix fuel additives (“thinners”, or similar additives) with diesel fuel.
Working in the engine compartmentSafety instructions on working in the engine compartment
Any work carried out in the engine compartment or on the
engine must be carried out cautiously.Before starting any work on the engine or in the engine compart-
ment:
1. Switch off the engine and remove the key from the ignition.
2. Apply the handbrake.
3. Move the gear stick to neutral or the selector lever to position P.
4. Wait for the engine to cool down.
5. Keep children away from the vehicle.
6. Raise the bonnet ⇒page 215.You should not do any work in the engine compartment unless you know
exactly how to carry out the jobs and have the correct tools! Have the work
carried out by a qualified workshop if you are uncertain.
All service fluids and consumables, e.g. coolant, engine oil, spark plugs and
batteries, are being constantly developed. SEAT provides a constant flow of
information to the Authorised Service Centres concerning modifications. For
this reason, we recommend you to have service fluids and consumables
replaced by an Authorised Service Centre. Please observe the relevant
instructions ⇒page 208. The engine compartment of any motor vehicle is a
hazardous area ⇒ .
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Checking and refilling levels
214
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 gea r 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 263. 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.
•
Always make sure you have not left any objects, such as cleaning cloths
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 belt s, 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
226Brake 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 diagram ⇒ page 273. 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 73.
WARNING
Before opening the bonnet to check the brake fluid level, read and observe
the warnings ⇒page 213.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 213 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.
It is important that you use only 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. 164 In the engine
compartment: Brake fluid
reservoir cover
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Checking and refilling levels227
Safety First
Operating instructions
Practical tips
Te c h n i c a l D a t a
•
Before opening the bonnet to check the brake fluid level, read and
observe the warnings ⇒page 213.
•
Brake fluid should be stored in the closed original container in a safe
place out of reach of children. There is a toxic risk.
•
Complete the brake fluid change according to the Maintenance
Program. 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.
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 batter ies. 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 smoki ng are prohibited. When handling
cables and electrical equipment, avoid causing sparks and electrostatic
WARNING (continued)

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 bat-
tery is under charge.

Keep children away from acid and batteries!
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Wheels and tyres233
Safety First
Operating instructions
Practical tips
Te c h n i c a l D a t a
Wear indicators
The original tyres on your vehicle have 1.6 mm high “tread wear indicators”
⇒
page 232, fig. 165 , running across the tread. Depending on the make,
there will be six to eight of them evenly spaced around the tyre. Markings on
the tyre sidewall (for instance the letters “TWI” or other symbols) indicate the
positions of the tread wear indicators. The minimum tread depth required by
law is 1.6 mm (measured in the tread grooves next to the tread wear indica-
tors). Worn tyres must be replaced. Different figures may apply in export
countries ⇒.
Tyre pressure
Incorrect tyre pressure causes premature wear and could cause tyre blow-out.
For this reason, the tyre pressure should be checked at least once per month
⇒ page 230.
Driving style
Fast cornering, heavy acceleration and hard braking all increase tyre wear.
Changing wheels around
If the front tyres are worn considerably more than the rear ones it is advisable
to change them around as shown ⇒page 232, fig. 166 . All the tyres will then
last for about the same time.
Wheel balance
The wheels on new vehicles are balanced. However, various factors encoun-
tered in normal driving can cause them to become unbalanced, which results
in steering vibration.
Unbalanced wheels should be rebalanced, as they otherwise cause excessive
wear on steering, suspension and tyres. A wheel must also be rebalanced
when a new tyre is fitted.
Incorrect wheel alignment
Incorrect wheel alignment causes excessive tyre wear, impairing the safety of
the vehicle. If tyres show excessive wear, you should have the wheel align-
ment checked by an Authorised Service Centre.
WARNING
There is a serious danger of accidents if a tyre bursts during driving!•
The tyres must be replaced at the latest when the tread is worn down to
the tread wear indicators. Failure to do so could result in an accident. Worn
tyres do not grip well at high speeds on wet roads. There is also a greater
risk of “aquaplaning”
•
At continuously high speeds, a tyre with insufficient pressure flexes
more. This causes it to overheat. This can cause tread separation and tyre
blow-out. Risk of accident. Always observe the recommended tyre pres-
sures.
•
If tyres show excessive wear, you should have the running gear checked
by an Authorised Service Centre.
•
Keep chemicals such as oil, fuel and brake fluid away from tyres.
•
Damaged wheels and tyres must be replaced immediately!For the sake of the environment
Under-inflated tyres will increase fuel consumption.Anti-puncture tyres
Anti-puncture tyres allow you to continue driving even with a
punctured tyre, in the majority of cases.Vehicles equipped with anti-puncture
21)
tyres from the factory indi-
cate the loss of tyre pressure on the instrument panel.
21)Depending upon version and country.
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Wheels and tyres
234
Driving with anti-puncture tyres (emergency gear)
– Leave the ESP/TCS (electronic stabilisation programme) switched on, or switch on ⇒page 185.
– Continue driving carefully and slowly (80 km/h maximum).
– Avoid sudden manoeuvres and sharp turns.
– Avoid driving over obstacles (for example kerbs) or potholes.
– Look out for the ESP/TCS intervening often, smoke coming from the tyres or the smell of rubber, the vehicle vibrating or a clat-
tering noise. If any of these occur, stop the vehicle.The anti-puncture tyres have a tag on the side of the tyre, with the description:
“DSST”, “Eufonia”, “RFT”, “ROF”, “RSC”, “SSR” or “ZP”.
The sides of this type of tyre are reinforced. When the tyres lose air they are
supported on the sides (emergency driving).
The loss of pressure in the tyre is shown on the instrument panel. You can
then drive a maximum of 80 km and if the circumstances are favourable (for
example, low load), even more.
The damaged tyre should be changed as soon as possible. The rim should be
checked in a specialist workshop to detect possible damage and replace it if
necessary. We recommend you contact Technical Service. If more than one
tyre is being used under emergency co nditions, this reduces the distance
which can be travelled.
Starting driving in emergency conditions
When the loss in tyre pressure is displayed on the instrument panel, this
implies that at least one tyre is being driven in emergency conditions ⇒.
End of emergency operation
Do not drive on if:
•
smoke is coming from one of the tyres,
•
there is a smell of rubber,
•
the vehicle vibrates,
•
there is a rattling noise.
When is it no longer possible to co ntinue driving even using anti-puncture
tyres?
•
If one of the tyres has been severely damaged in an accident, etc. If a tyre
has been badly damaged there is a risk that parts of the tread can be thrown
off and cause damage to the fuel lines, brake pipes or fuel filler.
•
It is also advisable to stop driving if severe vibrations occur, or if the wheel
starts overheating and gives off smoke.
WARNING
When driving in emergency conditions, the driving quality of the vehicle is
considerably impaired.•
The maximum permitted speed of 80 km/h is subject to road and
weather conditions. Please observe legal requirements when doing so.
•
Avoid sharp turns and rapid manoeuvres, and brake earlier than usual.
•
Avoid driving over obstacles (for example kerbs) or potholes.
•
If one or more tyres is being driven in emergency conditions, the driving
quality of the vehicle is impaired and there is a risk of accident.Note
•
The anti-puncture tyres do not “deflate” on losing pressure because they
are supported on the reinforced sides. Th erefore defects in the tyre can not be
detected with a visual inspection.
•
Snow chains must not be used on front tyres used in emergency
conditions.
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Wheels and tyres235
Safety First
Operating instructions
Practical tips
Te c h n i c a l D a t a
New tyres and wheels
New tyres and wheels have to be run-in.The tyres and wheel rims are an essential part of the vehicle's design. The
tyres and rims approved by SEAT are specially matched to the characteristics
of the vehicle and make a major contribution to good road holding and safe
handling ⇒.
Tyres should be replaced at least in pairs and not individually (i.e. both front
tyres or both rear tyres together). A knowledge of tyre designations makes it
easier to choose the correct tyres. Radial tyres have the tyre designations
marked on the sidewall, for example: 195/65 R15 91T
This contains the following information:
195 Tyre width in mm
65 Height/width ratio in %
R Tyre construction: Radial
15 Rim diameter in inches
91 Load rating code
T Speed rating
The tyres could also have the following information:•
A direction of rotation symbol
•
“Reinforced” denotes heavy-duty tyres.
The manufacturing date is also indicated on the tyre sidewall (possibly only
on the inner side of the wheel).
“DOT ... 1103...” means, for example, that the tyre was produced in the 11th
week of 2003.
We recommend that work on tyres and wheels is carried out by an Authorised
Service Centre. They are familiar with the procedure and have the necessary special tools and spare parts as well as the proper facilities for disposing of
the old tyres.
Any Authorised Service Centre has full information on the technical require-
ments when installing or changing tyres, wheels or wheel trims.
WARNING
•
We recommend that you use only wh
eels and tyres which have been
approved by SEAT for your model. Failure to do so could impair vehicle
handling. Risk of accident.
•
Avoid running the vehicle on tyres th at are more than six years old. If
you have no alternative, you should drive slowly and with extra care at all
times.
•
Never use old tyres or those with an unknown “history of use”.
•
If wheel trims are retrofitted, you must ensure that the flow of air to the
brakes is not restricted. This could cause them to overheat.
•
All four wheels must be fitted with radial tyres of the same type, size
(rolling circumference) and the same tread pattern.For the sake of the environment
Old tyres must be disposed of accordi ng to the laws in the country concerned.
Note
•
For technical reasons, it is not generally possible to use the wheels from
other vehicles. This can also apply to wheels of the same model. The use of
wheels or tyres which have not been approved by SEAT for use with your
model may invalidate the vehicle's type approval for use on public roads.
•
If the spare tyre is not the same as the tyres that are mounted on the
vehicle - for example with winter tyres - you should only use the spare tyre for
a short period of time and drive with extra care. Refit the normal road wheel
as soon as possible.
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Wheels and tyres
236Wheel bolts
Wheel bolts must be tightened to the correct torque.The design of wheel bolts is matched to the rims. If different wheel rims are
fitted, the correct wheel bolts with the right length and correctly shaped bolt
heads must be used. This ensures that wheels are fitted securely and that the
brake system functions correctly.
In certain circumstances, you may not use wheel bolts from a different car -
even if it is the same model ⇒page 208.
After the wheels have been changed, the tightening torque of the wheel bolts
should be checked as soon as possible with a torque wrench ⇒. The tight-
ening torque for steel and alloy wheels is 120 Nm.
WARNING
If the wheel bolts are not tightened correctly, the wheel could become
loose while driving. Risk of accident.•
The wheel bolts must be clean and turn easily. Never apply grease or oil
to them.
•
Use only wheel bolts which belong to the wheel.
•
If the torque of the wheel bolts is to o low, they could loosen whilst the
vehicle is in motion. Risk of accident! If the tightening torque is too high,
the wheel bolts and threads can be damaged.Caution
The prescribed torque for wheel bolts for steel and alloy wheels is 120 Nm.
Winter tyres
Winter tyres will improve the vehicles handling on snow and
ice.In winter conditions winter tyres will considerably improve the vehicles
handling. The design of summer tyres (width, rubber compound, tread
pattern) gives less grip on ice and snow.
Winter tyres must be inflated to a pressure 0.2 bar higher than the pressures
specified for summer tyres (see sticker on tank flap).
Winter tyres must be fitted on all four wheels.
Information on permitted winter tyre sizes can be found in the vehicle's regis-
tration documents. Use only radial winter tyres. All tyre sizes listed in the
vehicle documentation also apply to winter tyres.
Winter tyres lose their effectiveness when the tread is worn down to a depth
of 4 mm.
The speed rating code ⇒page 235, “New tyres and wheels” determines the
following speed limits for winter tyres: ⇒
Q max. 160 km/h
S max. 180 km/h
T max. 190 km/h
H max. 210 km/h
In some countries, vehicles which can exceed the speed rating of the fitted
tyre must have an appropriate sticker in the driver's field of view. These
stickers are available from your Authorised Service Centre. The legal require-
ments of each country must be followed.
Do not have winter tyres fitted for unnecessarily long periods. Vehicles with
summer tyres handle better when the roads are free of snow and ice.
If you have a flat tyre, please refer to the notes on the spare wheel
⇒ page 235, “New tyres and wheels”.
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If and when
240reliably 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 ve hicle. 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.
WARNING
Put the hazard warning lights on and place 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
–Pull off the hub cap. Also see ⇒page 241.
– Slacken the wheel bolts .
– Raise the car with the jack in the corresponding zone.
– Remove the wheel and then mount the spare wheel.
– Lower the vehicle.
– Tighten the wheel bolts firmly with the box spanner.
–Replace the hub cap.
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