2014 SEAT IBIZA MK4 Service and Repair Manual
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Workshop Manual
Ibiza 2008 ➤
Ibiza ST 2010 ➤
Toledo 2013 ➤
02R 5-speed manual gearbox
Edition 12.2012
Service
Service Department. Technical Information
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Service
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Code, engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Filling quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2 Gaskets, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3 Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.4 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.5 Bolts, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.6 Antifriction bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.7 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.8 Synchromesh rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.9 Gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.10 Mobile pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.11 Coupling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Clutch mechanism: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Clutch actuation: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Mounting bracket with clutch master cylinder: Removing and installing . . . . . . . . . . . . . . 16
1.5 Clutch pedal with over-centre spring: Removing and installing, left-hand drive vehicles . . 19
1.6 Clutch pedal: Removing and installing, right-hand drive vehicles . . . . . . . . . . . . . . . . . . . . 22
1.7 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.8 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.9 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.10 Clutch slave cylinder: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Clutch release assembly: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Clutch: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Gear mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Gear selection mechanism: installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Gear stick handle with cover - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3 Removing and installing the gear stick handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.4 Gear selection mechanism:installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5 Gear selection mechanism cables: removing and fitting; general overview . . . . . . . . . . . . 44
1.6 Gear selection mechanism: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.7 Gear selection mechanism: Adjust convergence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Gearbox Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Removing and installing the gearbox, Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . 54
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
Contents i
2.2 Gearbox Removing and installing, Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4 Gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.1 Check and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5 Gearbox Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2 assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.3 Assembly overview - removing and installing cover for gearbox housing and 5th gear . . . . 86
5.4 Removing and installing gearbox housing and selector mechanism - Assembly overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.5 Removing and installing input shaft, output shaft, differential and selector rods - Assembly
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.6 Assembly sequence - removing and installing cover for gearbox housing and 5th gear . . 89
5.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 95
6 Gearbox casing and clutch housing: Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7 Selector unit (gearbox side) disassembly and assembly (selector shaft can be removed from
the selector cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8 Selector unit (gearbox side) disassembly and assembly (selector shaft cannot be removed
from the selector cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Input shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Input shaft: Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Input shaft: setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Secondary shaft: Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Secondary shaft: setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3 Reverse gear shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1 Replace seals for flanged shafts with installed equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Distinguishing seals for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.3 Renewing seal (two-part seal and sleeve for right flange shaft) . . . . . . . . . . . . . . . . . . . . . . 159
1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) . . . . 162
2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3 Differential assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.1 Differential: Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.2 Differential: Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
ii Contents
00 – Technical data
1 Gearbox identification
(ERL002280; Edition 12.2012)
⇒ “4 Code, engine allocation”, page 5 .
⇒ “5 Filling quantity”, page 7 .
Location on gearbox
Identification letters and date of manufacture -arrow 1-, type of
gearbox -arrow 2-.
Gearbox type
5-speed manual gearbox 02R -arrow 2-.
Engine code and manufacture date of gearbox
Example: EWR 11 09 1
I I I l
I I I l
Engine code Day Month Model year 2001
Additional data depend on manufacture.
Note
The gearbox identification letters can also be found on the vehicle
data sticker.
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
02R 5-speed manual gearbox - Edition 12.2012
1. Gearbox identification 1
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What's Included?
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Print one or all pages of your manual
$37.99
The 2014 SEAT IBIZA MK4 Service and Repair Manual is a comprehensive guide for maintaining and fixing your SEAT IBIZA MK4 model. This manual is specifically designed for the 2014 model year, providing detailed instructions and diagrams to assist car owners and mechanics in servicing and repairing their vehicles.
- Includes step-by-step procedures for routine maintenance tasks like oil changes, filter replacements, and brake inspections.
- Covers troubleshooting and diagnostic procedures for various systems, including the engine, electrical system, transmission, and more.
- Provides specifications and torque values for various components to ensure accurate repairs.
- Features detailed wiring diagrams and illustrations to aid in understanding and repairing complex electrical systems.
- Contains comprehensive repair instructions for engine components, suspension, steering, brakes, and other major systems.
- Compiled by experienced technicians and automotive experts, ensuring accuracy and reliability.
