How to Replace Engine Thermostat on SEAT Cordoba Saloon (6K1, 6K2)

Introduction

This guide provides instructions for replacing the engine thermostat on SEAT Cordoba Saloon (6K1, 6K2) models. It is based on a similar procedure for an Audi A4 Saloon (8D2, B5) 1.6, and steps may vary slightly depending on the car's design.

Important Notes:

• This procedure can be used for SEAT Cordoba Saloon (6K1, 6K2) 1.6 i and SEAT Cordoba Saloon (6K1, 6K2) 1.8 T 20V Cupra.
• Always perform work with the engine stopped.
• Check the coolant condition and change it if necessary during replacement.

Tools You Might Need

• Wire brush
• All-purpose cleaning spray
• Electronic spray
• Sealant
• Torque wrench
• Combination spanner #10
• Combination spanner #13
• Combination spanner #17
• Combination spanner #46
• Drive socket #10
• Drive socket #13
• HEX bit No.H5
• HEX bit No.H8
• Ratchet wrench
• Funnel
• Fluid container
• Pincers
• Fender cover

Replacement Procedure

1. Step 1: Open the hood.

   [Image: A hand opening the hood of a car.]

2. Step 2: Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.

   [Image: A fender protection cover being placed on a car fender.]

3. Step 3: Unscrew the engine cover fastener using HEX No.H5 and a ratchet wrench.

   [Image: A HEX bit being used to unscrew a fastener on the engine cover.]

4. Step 4: Remove the engine cover.

   [Image: The engine cover being lifted off the engine.]

5. Step 5: Unscrew the coolant reservoir cap.

   [Image: A hand unscrewing the cap of a coolant reservoir.]

6. Step 6: Prepare a container for fluids.

   [Image: A container being placed under a car component to catch fluids.]

7. Step 7: Clean the coolant hose using all-purpose cleaning spray.

   [Image: All-purpose cleaning spray being applied to a coolant hose.]

8. Step 8: Disconnect the coolant pipe retaining clip.

   [Image: A hand disconnecting a retaining clip from a coolant pipe.]

9. Step 9: Detach the coolant hose.

   [Image: A coolant hose being detached from its connection point.]

10. Step 10: Drain the coolant from the engine.

    [Image: Coolant draining from the engine into a container.]

    Caution: Coolant can be very hot. Wear gloves to prevent contact with hot liquid. Wait until the coolant has completely flowed out.

11. Step 11: Clean the coolant hose using all-purpose cleaning spray.

    [Image: All-purpose cleaning spray being applied to a coolant hose.]

12. Step 12: Attach the coolant hose.

    [Image: A coolant hose being reconnected.]

13. Step 13: Connect the coolant pipe retaining clip.

    [Image: A retaining clip being connected to a coolant pipe.]

14. Step 14: Clean the coolant hose using all-purpose cleaning spray.

    [Image: All-purpose cleaning spray being applied to a coolant hose.]

15. Step 15: Pull aside the V-ribbed belt tensioner pulley using a combination spanner #17.

    [Image: A spanner being used to move the V-ribbed belt tensioner pulley.]

16. Step 16: Remove the V-ribbed belt.

    [Image: The V-ribbed belt being removed from the pulleys.]

    Tip: Check the condition of the tensioner pulley and idler pulley. Replace them if necessary.

17. Step 17: Return the tensioner pulley to its initial position.

    [Image: The tensioner pulley being returned to its resting position.]

18. Step 18: Remove the battery cover.

    [Image: The battery cover being removed.]

19. Step 19: Unscrew the fasteners of the car battery terminals using a combination spanner #10.

    [Image: A spanner being used to unscrew battery terminal fasteners.]

20. Step 20: Remove the battery terminals.

    [Image: Battery terminals being disconnected from the battery.]

21. Step 21: Loosen the alternator fasteners using HEX No.H8.

    [Image: A HEX bit being used to loosen alternator fasteners.]

22. Step 22: Unscrew the fastener of the viscous fan clutch using a combination spanner #46 and HEX No.H8.

    [Image: A spanner and HEX bit being used on the viscous fan clutch fastener.]

23. Step 23: Loosen the alternator fasteners using HEX No.H8.

    [Image: A HEX bit being used to loosen alternator fasteners.]

24. Step 24: Remove the alternator.

    [Image: The alternator being removed from its mounting.]

25. Step 25: Disconnect the alternator connector.

    [Image: An electrical connector being disconnected from the alternator.]

26. Step 26: Unscrew the alternator power cable fastener using a combination spanner #13.

    [Image: A spanner being used to unscrew the alternator power cable fastener.]

27. Step 27: Clean the thermostat housing using all-purpose cleaning spray.

    [Image: All-purpose cleaning spray being applied to the thermostat housing.]

28. Step 28: Unscrew the thermostat housing fasteners using a drive socket #10 and a ratchet wrench.

    [Image: A socket wrench being used to unscrew thermostat housing fasteners.]

29. Step 29: Remove the thermostat housing.

    [Image: The thermostat housing being removed from the engine block.]

30. Step 30: Remove the thermostat using pincers.

    [Image: Pincers being used to extract the old thermostat.]

    Caution: Do not apply excessive force when removing the part, as this may damage it. Coolant may leak out.

31. Step 31: Clean the thermostat housing mounting seat using a wire brush and all-purpose cleaning spray.

    [Image: A wire brush and spray being used to clean the thermostat housing seat.]

32. Step 32: Install a new thermostat.

    [Image: A new thermostat being placed into the housing seat.]

33. Step 33: Treat the thermostat housing with a sealant.

    [Image: Sealant being applied to the thermostat housing gasket or mating surface.]

34. Step 34: Install the thermostat housing.

    [Image: The thermostat housing being fitted onto the engine block.]

    Tip: When installing, do not use excessive force to avoid damage to the part.

35. Step 35: Tighten the thermostat housing fasteners using a drive socket #10 and a torque wrench. Tighten to 6 Nm torque.

    [Image: A torque wrench being used to tighten thermostat housing fasteners.]

36. Step 36: Tighten the alternator power cable fastener using a drive socket #13 and a torque wrench. Tighten to 5 Nm torque.

    [Image: A torque wrench tightening the alternator power cable fastener.]

37. Step 37: Connect the alternator connector.

    [Image: The alternator electrical connector being plugged in.]

38. Step 38: Install the alternator.

    [Image: The alternator being mounted back onto the engine.]

39. Step 39: Tighten the alternator fasteners using HEX No.H8 and a torque wrench. Tighten to 8 Nm torque.

    [Image: A torque wrench tightening alternator fasteners.]

40. Step 40: Tighten the fastener of the viscous fan clutch using a combination spanner #46 and HEX No.H8. Use a torque wrench. Tighten to 24 Nm torque.

    [Image: A torque wrench tightening the viscous fan clutch fastener.]

41. Step 41: Pull aside the V-ribbed belt tensioner pulley using a combination spanner #17.

    [Image: A spanner being used to move the V-ribbed belt tensioner pulley.]

42. Step 42: Install the V-ribbed belt.

    [Image: The V-ribbed belt being placed onto the pulleys.]

43. Step 43: Return the tensioner pulley to its initial position.

    [Image: The tensioner pulley being released to tension the V-ribbed belt.]

    Tip: Check the condition of the tensioner pulley and idler pulley. Replace them if necessary.

44. Step 44: Remove the coolant reservoir cap.

    [Image: A hand removing the coolant reservoir cap.]

45. Step 45: Insert the funnel.

    [Image: A funnel being inserted into the coolant reservoir opening.]

46. Step 46: Pour coolant into the coolant reservoir.

    [Image: Coolant being poured into the coolant reservoir via a funnel.]

    Recommendations: Only use the coolant recommended by the manufacturer. The coolant level should be at the MAX mark. Wait until the air goes out of the system.

47. Step 47: Attach the terminals to the battery.

    [Image: Battery terminals being connected to the battery posts.]

    Tip: Be careful! Do not mix up the positive and the negative terminals of the car battery.

48. Step 48: Screw in the fasteners of the battery terminals using a combination spanner #10.

    [Image: A spanner tightening the battery terminal fasteners.]

49. Step 49: Treat the battery terminals with dielectric grease.

    [Image: Dielectric grease being applied to battery terminals.]

50. Step 50: Install the battery cover.

    [Image: The battery cover being placed back over the battery.]

51. Step 51: Run the engine for a few minutes to remove residual air from the cooling system and check component operation.

    [Image: The car engine running.]

52. Step 52: Shut off the engine.

    [Image: A hand turning off the ignition key or pressing a start/stop button.]

53. Step 53: Install the coolant reservoir cap.

    [Image: A hand placing the coolant reservoir cap on the reservoir.]

54. Step 54: Screw on the coolant reservoir cap.

    [Image: A hand screwing the coolant reservoir cap tightly.]

55. Step 55: Install the engine cover and secure it.

    [Image: The engine cover being placed back and secured.]

56. Step 56: Screw in the engine cover fasteners using HEX No.H5 and a ratchet wrench.

    [Image: A ratchet wrench tightening engine cover fasteners.]

    Recommendation: Do not use excessive force during installation, as this may damage the part.

57. Step 57: Check the coolant level. If necessary, top up to the required level.

    [Image: A person checking the coolant level in the reservoir.]

58. Step 58: Remove the fender protection cover.

    [Image: A fender protection cover being removed.]

59. Step 59: Close the hood.

    [Image: A hand closing the car hood.]

WELL DONE! ?

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Disclaimer

The document contains only general recommendations that may be useful for you when you perform repair or replacement work. AUTODOC shall not be liable for any loss, injury, damage of property occurring in the repair or replacement process due to incorrect use or misinterpretation of the provided information. AUTODOC shall not be liable for any possible mistakes and uncertainties in this guide. The information provided is for information purposes only and cannot replace advice from specialists.

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