Haynes Seat Ibiza and Malaga Owners Workshop Manual 1850106096, 9781850106098

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WESTERN EDUCATION AND LIBRARY BOARD. LIBRARY SERVICE.

luding special/limited 2c and 1461 cc petrol

Books can be renewed, by personal application, post or telephone, quoting latest date, author and book number.

NO RENEWALS CAN BE GRANTED FOR A BOOK RESERVED BY ANOTHER READER. Readers are expected to take care of books. Lost or damaged books must be paid for by the borrower concerned.

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Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

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Acknowledgements Thanks are due to Champion Spark Plug who supplied the illustrations showing spark plug conditions, to Holt Lloyd Limited who supplied the illustrations showing bodywork repair, and to Duckhams Oils who provided lubrication data. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual.

Restoring and Preserving our Motoring Heritage Few people can have had the luck to realise their dreams to quite the same extent and in such a remarkable fashion as John Haynes, Founder and Chairman of the Haynes Publishing Group. Since 1965 his unique approach to workshop manual publishing has proved so successful that millions of Haynes Manuals are now sold every year throughout the world, covering literally thousands of different makes and models of cars, vans and motorcycles. A continuing passion for cars and motoring led to the founding in 1985 of a Charitable Trust dedicated to the restoration and preservation of our motoring heritage. To inaugurate the new Museum, John Haynes donated virtually his entire private collection of 52 cars. Now with an unrivalled international collection of over 210 veteran, vintage and classic cars and motorcycles, the Haynes Motor Museum in Somerset is well on the way to becoming one of the most interesting Motor Museums in the world. A 70 seat video cinema, a cafe and an extensive motoring bookshop, together with a specially constructed one kilometre motor circuit, make a visit to the Haynes Motor Museum atruly unforgettable experience. Every vehicle in the museum is preserved in as near as possible mint condition and each car is run every six months on the motor circuit. Enjoy the picnic area set amongst the rolling Somerset hills. Peer through the William Morris workshop windows at cars being restored, and browse through the extensive displays of fascinating motoring memorabilia. From the 1903 Oldsmobile through such classics as an MG Midget to the mighty ‘E’ type Jaguar, Lamborghini, Ferrari Berlinetta Boxer, and Graham Hill’s Lola Cosworth, there is something for everyone, young and old alike, at this Somerset Museum.

© Haynes Publishing 1995 A book in the Haynes Owners Workshop Manual Series Printed by J. H. Haynes & Co. Ltd., Sparkford, Nr Yeovil, Somerset BA22 7JJ, England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 85010 609 6 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library

Haynes Motor Museum We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Situated mid-way between London and Penzance, the Haynes Motor Museum is located just off the A303 at Sparkford, Somerset (home of the Haynes Manual) and is open to the public 7 days a week all year

round, except Christmas Day and Boxing Day. Telephone 01963 440804.

Contents Page

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Component key Battery Starter motor Alternator and regulator Ignition/starter switch Hazard lights switch Tailgate wiper/washer switch Courtesy light switch Front LH door lock switch OANOORWNH Lighting switch Horn button Windscreen wiper/washer switch Heater fan speed resistor Instrument panel potentiometer Sidelights switch

72 73 74 75s 76 77 78 79 80 81 82 83 84 85

Oil pressure switch Brake stop lamps switch

86 87 88

Re\ ersing light switch Heater fan switch Air conditioning switch — where fitted Heater rear window switch Radiator fan switch Handbrake switch Front foglamp switch Rear foglamp switch \ Electric window LH door switch Electric window LH door switch in RD door Parking lamps switch Direction indicators switch Courtesy light LH door switch Courtesy light RH door switch Choke switch Fuel cut-off device Electric window RH door switch Fuel-injection throttle valve switch Temperature gauge sender unit Fuel gauge/warning light sender unit Low brake fluid sender unit Low engine oil level sender unit Oil pressure sender unit Oil pressure gauge LH brake pad wear indicator RH brake pad wear indicator Tachometer (rev-counter) Fuel level gauge Coolant temperature gauge Windscreen washer reservoir level sensor Not applicable (Diesel models) Not applicable (Diesel models) Air conditioning air temperature sensor — where fitted Air conditioning anti-icing thermo-switch — where fitted Air conditioning radiator thermo-switch — where fitted Air conditioning dehydrator filter pressostat — where fitted Air conditioning vacuum electrovalve — where fitted Air conditioning idle speed increase vacuum electrovalve — where fitted Air conditioning water electrovalve — where fitted Speedometer transmitter - electronic type Speedometer - electronic type Fuel-injection injectors Fuel-injection lambda probe Fuel-injection airflow meter Fuel-injection auxiliary air valve Fuel-injection engine temperature sensor Fuel-injection air temperature sensor Horn Main interconnection terminal box Instrument panel ; Secondary terminal box Not applicable (Diesel models) Air conditioning control unit electronic circuit — where

fitted Fuel-injection ECU Windscreen wiper relay

89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 sz 138 139 140 141

142 143. 144

Direction indicator and hazard lights relay Check control module — where fitted Horn relay Heated rear window relay Headlamp main beam relay Services feed relay Electric windows relay Central locking relay Headlamp dip beam relay Dim-dip inverter relay Dim-dip relay

Air conditioning 1st speed fan relay Air conditioning radiator fan relay Air conditioning compressor relay Air conditioning electro-magnetic clutch relay Headlamp washer relay Fuel injection control unit relay Sidelights ON warning light Main beams ON warning light

Direction indicator ON warning light Alternator charge warning light Rear foglamp ON warning light Oil pressure warning light Low fuel level warning light

Hazard lights ON warning light Heated rear window ON warning light Low windscreen washer fluid warning light Low brake fluid/brake pad wear warning light Low engine oil level warning light Brake stop lamp bulb failure warning light Handbrake ON warning light Not applicable (diesel models only) Choke ON warning light Front foglamp ON warning light

Courtesy light RH switchbox LH switchbox Heater control

bulb illumination not found on diagrams illumination not found on diagrams illumination bulb

Cigar lighter bulb Instrument panel bulb Instrument panel bulb Instrument panel bulb Instrument panel bulb Rear luggage compartment bulb Headlamp LH lower beam bulb Headlamp RH lower beam bulb

Rear LH direction indicator bulb Rear RH direction indicator bulb Front LH direction indicator bulb Front RH direction indicator bulb Headlamp LH main beam bulb Headlamp RH main beam bulb Brake stop lamp LH bulb Brake stop lamp RH bulb Tail lamp LH bulb Tail lamp RH bulb

Rear foglamp bulb Reversing lamp bulb Front LH sidelight bulb Front RH sidelight bulb Direction indicator LH repeater bulb Direction indicator RH repeater bulb Front foglamp RH bulb Front foglamp LH bulb Ignition coil Hall effect transmitter Electronic ignition module - carburettor models Electronic ignition module - fuel-injection models Distributor ‘Spark plug HT leads Spark plugs Radio/cassette installation point

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Chapter 12

Electrical system

Component key (continued)

145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166

RH loudspeaker Fuses in terminal box Fuel-injection air fuse Cigar lighter Radiator fan motor Heater fan motor Electric windows RH door motor Electric windows LH door motor Tailgate wiper motor Windscreen wiper motor Central locking front LH door lock motor Central locking rear LH door lock motor Central locking rear RH door lock motor Central locking tailgate/bootlid lock motor Windscreen washer pump motor Tailgate washer pump motor Headlamp washer pump motor Internal fuel pump -— fuel-injection models External fuel pump - fuel-injection models RH headlamp wiper motor LH headlamp wiper motor Number plate RH lamp bulb

167 168 169 170 171 172

Number plate LH lamp bulb Analogue clock Digital clock Heated rear window element Dim-dip resistor Fuse

Wire colour key Black BK Blue BL

BR G GR LB O P

R V W Y

Brown Green Grey Light blue Orange Pink Red Violet White Yellow

263

Index A

Caliper - 169

About this manual — 5 Accelerator cable carburettor engines — 112 fuel-injected engines — 128 Accelerator pedal carburettor engines - 113 fuel-injected engines - 129 Acknowledgements - 2 Aerial — 238 Air cleaner - 39 carburettor engines — 108 fuel-injected engines - 128 Alternator - 50, 222 Anti-roll bar - 184 Antifreeze — 39

B Balljoints front suspension - 186 track rod end - 194 Battery - 50, 220, 221 Bearings

big-end - 90, 92 clutch release - 149 hub — 180, 187 main — 89, 90

Big-end bearings - 90, 92 Bleeding (brakes) - 164

Blower motor - 103 Bodywork and fittings - 50, 196 et seq Bodywork repair - see colour pages between pages 32 and 33 Bonnet - 202 Booster battery starting — 16 Boot lid - 210 Brake fluid — 47 Brake hoses - 48, 165 Braking system - 47, 161 et seq Bulb renewal clock illumination — 231 courtesy lamp - 230 direction indicator — 228 glove compartment illumination — 231 hazard warning switch illumination - 23 headlamp - 228 ‘ indicator - 228 instrument panel illumination — 231 luggage compartment — 230 number plate lamp - 228 parking lamp - 228 rear lamp cluster — 228 sidelamp - 228 Bumpers — 198

Camshaft 903 cc OHV engine - 83 1193 cc and 1461 cc OHC engines - 67 Capacities — 29 Carburettor - 114,115 Cassette player — 237 Centre console - 215 Charging system - 221 Choke cable - 113 Cigar lighter — 234 Clock - 231, 234 Clutch - 46, 147 et seq CO level adjustment — 40 Compressicn test 903 cc OHV engine - 58 1193 cc. and 1461 cc OHC engines - 65 Condenser - 42 Connecting rod assemblies - 84, 88, 92 Console - 215 Contact breaker points - 42 Conversion factors — 17 Cooling, heating and ventilation systems — 37, 94 et seq Courtesy lamp - 227, 230 Crankcase - 85 Crankcase ventilation system carburettor engines — 127 fuel-injected engines - 135 Crankshaft — 85, 89, 90

oil seals 903 cc OHV engine - 63 1193 cc and 1461 cc OHC engines - 72 Cross-shaft (braking system) — 162 CV joint (driveshaft) — 47, 159 Cylinder block — 85 Cylinder head - 78, 81, 82 903 cc OHV engine - 59 1193 cc and 1461 cc OHC engines - 65

D Depressurisation (fuel system) - 129 Dimensions - 6 Direction indicator — 228, 231 Disc - 170 Distributor — 45 contact breaker ignition system — 139 electronic ignition system - 144 Doors - 203, 205, 206, 210, 227 Draining (cooling system) - 38 Drivebelt (alternator) — 50 Driveshafts - 47, 157 et seq Drum - 172

Cc Cables accelerator carburettor engines — 112 fuel-injected engines - 128 bonnet release — 202 choke carburettor engines — 113 clutch — 46, 147 handbrake - 175 heater control — 103 speedometer — 234

E Electrical system — 50, 218 et seq Engine — 36, 52 et seq Exhaust manifold carburettor engines - 124 fuel-injected engines — 135 Exhaust system — 42 carburettor engines — 124 fuel-injected engines — 135 Expansion tank — 97

Index

265

F

J

Facia — 216, 227

Jacking - 7 Jump starting - 16

Fan heater — 103

radiator — 95, 96 Fault diagnosis — 18 Filling (cooling system) - 38 Flushing (cooling system) — 38 Flywheel 903 cc OHV engine - 63 1193 cc and 1461 cc OHC engines - 73 Fuel, exhaust and emission control systems — 39, 105 et seq Fuel filter — 40, 130

Fuel gauge sender unit carburettor engines — 111 fuel-injected engines — 130 Fuel-injection system - 127 et seq Fuel pump carburettor engines — 110 fuel-injected engines — 129, 130 Fuel tank carburettor engines — 111, 112 fuel-injected engines - 130 Fuses — 226

G Gaiters driveshaft — 47, 159 steering gear - 193 Gearbox -— 47, 78, 150 et seq Gearchange linkage/mechanism - 152 Glovebox — 217, 231

Ha Handbrake - 175, 176 Hazard warning switch illumination — 231 Headlamp — 51, 228, 231, 237 Heater - 101 to 104 Horn -— 234 HT leads - 45 Hubs front — 180, 182 rear —- 187 Hydraulic fluid — 47 Hydraulic hoses - 48, 165 Hydraulic system — 164 Hydraulic tappets — 67

Idle speed adjustment — 40 Ignition advance module — 146 Ignition amplifier module — 146 Ignition coil contact breaker ignition system — 140 electronic ignition system — 145 Ignition switch — 192, 226 Ignition system — 42, 136 et seq Ignition timing contact breaker ignition system — 43 electronic ignition system — 146 Indicators — 228, 231 Inlet air temperature control system — 109 Inlet manifold carburettor engines — 99, 123 fuel-injected engines - 134 Instrument panel - 228, 231, 232 Introduction to the SEAT Ibiza & Malaga - 5

L Leaf spring - 188 Locks bonnet — 202 boot lid - 210 door - 206 steering - 192 tailgate - 211 Loudspeakers — 238 Lower balljoint (suspension) — 186 Lubricants and fluids - 29 Luggage compartment illumination — 230

Main bearings — 89, 90 Manifolds exhaust carburettor engines — 124 fuel-injected engines — 135 inlet carburettor engines — 123 fuel-injected engines — 134 Master cylinder - 166 Matrix (heater) — 102 Mirror — 210 Mixture adjustment — 40 MOT test checks - 24 Mountings 903 cc OHV engine - 63 1193 cc and 1461 cc OHC engines — 73

N Number plate lamp - 228, 231

O Oil pump 903 cc OHV engine - 61

1193 cc and 1461 cc OHC engines - 71 Oil seals 903 cc OHV engine - 63 1193 cc and 1461 cc OHC engines - 72 gearbox - 154

P

Pads — 47, 167

Parking lamp — 228 Pedals accelerator carburettor engines - 113 fuel-injected engines - 129 brake - 162 clutch - 148 Pistons — 84, 88, 92 Points — 42 Pressure check (fuel system) - 129 Pressure regulating valve (braking system) - 171

266

Index

R

handbrake warning light- 176 . ignition - 192, 226

Radiator — 97 Radiator grille — 201 Radio — 237, 238 Rear lamp cluster — 228, 231 Rear window - 212 Relays — 226 Release bearing (clutch) - 149 Repair procedures - 11 Reversing lamp switch — 155 Rotor arm - 45 Routine maintenance - 27 et seq bodywork - 50, 196 braking system — 47 clutch — 46 cooling, heating and ventilation systems — 37 driveshafts — 47 electrical system — 50 engine - 36 fuel and exhaust systems — 39 gearbox -— 47 ignition system — 42 suspension and steering — 48

Ss Safety first — 9

instrument panel illumination rheostat — 228 reversing lamp — 155 steering column multi-function — 227 stop lamp - 177 Swivel hub assembly - 182

Tt Tailgate — 211,212 Tailgate wiper - 51, 236 Tappets

903 cc OHV engine - 83 1193 cc and 1461 cc OHC engines - 67 Temperature gauge sender unit — 96 Thermostat — 98, 99 Tie-bar — 186 Timing belt and sprockets (1193 cc and 1461 cc OHC engines) — 67 Timing cover, chain and sprockets (903 cc OHV engine) - 60 Tools - 12 Top Dead Centre (TDC) for number one piston 903 cc OHV engine — 58 1193 cc and 1461 cc OHC engines - 65 Torsion bars (boot lid) — 210 Towing - 7 Track control arm (suspension) — 185

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electrical system — 219 electronic ignition system — 141 fuel system - 107, 127 Seat belts - 214 Seats - 213

Servicing — 27 et seg bodywork - 50, 196 braking system - 47 clutch - 46 ‘cooling, heating and ventilation systems — 37 driveshafts — 47 electrical system - 50 engine - 36 fuel and exhaust systems - 39 gearbox — 47 ignition system — 42 suspension and steering - 48 Servo - 163, 164 Shock absorber - 187 Shoes -— 48, 173 Side windows - 212, 213 Sidelamp - 228 Spare parts - 8 Spark plug conditions - see co/our pages between pages 32 and 33 Speakers - 238 Speedometer - 154, 234 Starter motor ~ 223, 224 Starting system — 223 Steering angles - 194

Track rod end balljoint — 194 Trim panels door —- 203 exterior — 213 interior —- 214 Tripode joint (driveshaft) — 159 Tyres - 48

U Unleaded petrol carburettor engines - 114

fuel-injected engines - 129

Vv Vacuum servo unit — 163, 164 Valve clearances (903 cc OHV engine) — 37 Valves - 81 Vehicle identification numbers — 8 Voltage regulator - 222

WwW

Steering column - 190, 191, 193, 227

Steering gear - 193, 194 Steering lock - 192 Steering wheel - 190 Stop lamp switch - 177 Sump 903 cc OHV engine - 61 __ 1193 cc and 1461 cc OHC engines - 70 Support struts (tailgate) — 211 Suspension andsteering - 48, 178 et seq Suspension strut - 184 Switches cooling fan — 96 courtesy lamp - 227 door - 227 facia - 227

Wash/wipe system - 51, 237 Water pump - 99 Weights - 6 Wheel alignment — 194 Wheel changing - 7 Wheel cylinder - 174 Wheels - 48 Windows - 205, 212, 213 Windscreen - 212

Windscreen wiper — 51, 234 Wing - 212 Wipers - 51, 234, 236 Wiring diagrams - 238 Wishbone - 189 Working facilities — 12

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